Heating, Ventilation and Air Conditioning Buick Century VI

Fastener Tightening Specifications

HVAC Fastener Tightening Specifications

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The heating, Ventilation and Air Conditioning (HVAC) system is divided into three sections. The first, Heating, Ventilation and Air Conditioning, has all procedures that pertain to a HVAC component or function that are not specifically associated with an automatic or manual control system. The second, HVAC System-Manual, has all procedures specific to the manual control system. The third, HVAC Systems-Automatic, has all the procedures specific to the automatic control system.

For systems with DTCs, begin the system diagnosis with the following procedures

1. «DIAGNOSTIC SYSTEM CHECK - HVAC SYSTEMS - MANUAL»(/buick/century/vi-1997-2005/remont/manual-hvac-system/#hvac-systems-manual) in HVAC Systems-Manual
2. «DIAGNOSTIC SYSTEM CHECK - HVAC SYSTEMS - AUTO»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#hvac-systems-automatic) in HVAC Systems-Automatic

The Diagnostic System Check will provide the following information

1. The identification of the control modules which command the system.
2. The ability of the control modules to communicate through the Class 2 serial data circuit.

The use of the Diagnostic System Check will identify and lead the technician to the correct diagnostic procedure.

Review the Description and Operation information to help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation. The HVAC Description and Operation information is divided into

1. AIR DELIVERY DESCRIPTION AND OPERATION in HVAC System-Manual
2. AIR TEMPERATURE DESCRIPTION AND OPERATION in HVAC Systems-Manual
3. AIR DELIVERY DESCRIPTION AND OPERATION in HVAC Systems-Automatic
4. AIR TEMPERATURE DESCRIPTION AND OPERATION in HVAC Systems-Automatic

The Air Delivery Description and Operation contains the following topics

1. HVAC Control Components
2. Air Speed
3. Air Distribution
4. Recirculation Operation
5. Automatic Operation

The Air Temperature Description and Operation contains the following topics

1. HVAC Control Components
2. Heating and A/C Operation
3. Automatic Operation
4. Engine Coolant
5. A/C Cycle

Refrigerant Leak Testing

Tools Required

1. J 39400-A Halogen Leak Detector. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. J 41447 R-134A A/C Tracer Dye-Box of 24. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. J 41459 R-134A A/C Tracer Dye Injector. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. J 42220 Universal 12V Leak Detection Lamp. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. J 43872 Fluorescent Dye Cleaner. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

The preferred method of leak testing is the use of fluorescent dye. J 41447 is the only dye approved by General Motors. Follow the Fluorescent Dye Injection procedure for vehicles that do not already contain the fluorescent dye.

Fluorescent Leak Detector

1. Fluorescent dye will assist in locating any leaks in the A/C system.
2. The J 41447 dye mixes and flows with the PAG oil throughout the refrigerant system. IMPORTANT: PAG oil is water soluble.
3. Condensation on the evaporator core or the refrigerant lines may wash the PAG oil and fluorescent dye away from the actual leak. Condensation may also carry dye through the HVAC module drain.
4. To prevent false diagnosis in the future, thoroughly clean the residual dye from any area where leaks were found. Use a rag and the approved fluorescent dye cleaner J 43872 .

Fluorescent Dye Injection

1. With the A/C system charged, add J 41447 to the A/C system using J 41459 Follow the instructions provided with J 41459
2. To prevent any false diagnosis, thoroughly clean any residual dye from the service port with a rag and the approved fluorescent dye cleaner J 43872 .
3. The dye injection package contains a notice sticker. Complete the leak detection information and place the sticker near the charge label.

A/C Compressor Shaft Seal Leak Detection with Dye

Use J 43872 to clean all traces of fluorescent dye from the A/C compressor shaft seal and reinspect the compressor.

1. Run the A/C system 15-30 minutes depending on the type of leak in order to circulate the dye.
2. Use J 42220 to inspect the A/C compressor shaft seal.
3. To prevent false diagnosis in the future, thoroughly clean any residual dye from the area of the leak with a rag and the approved fluorescent dye cleaner J 43872 .

Service Ports

The sealing cap is the primary seal for the service ports. The cap contains an O-ring gasket that provides a leak-free seal. Install the cap tightly for leak-free sealing. The following conditions will cause a refrigerant loss

1. A loose cap
2. A missing cap
3. An incorrect cap

Use J 42220 or J 39400-A in order to test the service ports and sealing caps for leaks.

To prevent a false diagnosis, thoroughly clean any residual dye from the service port or sealing cap with a rag and the approved fluorescent dye cleaner J 43872 .

Evaporator Core

Use J 42220 in order to inspect the HVAC drain port. Follow the Fluorescent Dye Injection procedure if the A/C system does not contain fluorescent dye.

If only J 39400-A is available complete the following steps

1. With the engine running, turn the A/C ON.
2. Select the maximum blower motor speed for at least 15 seconds.
3. Turn OFF the engine.
4. Turn OFF the blower motor.
5. Wait 10 minutes.
6. Turn ON the blower motor and select the lowest speed.
7. Insert the leak detector probe into one of the center instrument panel outlets. Try to get as close to the evaporator as possible.
8. A solid alarm on the detector indicates a leak.

Halogen Leak Detector

Ensure that the vehicle has at least 0.45 kg (1 lb) of refrigerant in the A/C refrigeration system in order to perform a leak test. Refer to REFRIGERANT RECOVERY AND RECHARGING for recharging the A/C system.

1. Windshield washing solutions
2. Many solvents and cleaners
3. Some adhesives used in the vehicle

Clean and dry all surfaces in order to prevent a false warning. Liquids will damage the detector.

The J 39400-A is a small unit that operates on 12 volts DC. The J 39400-A provides an audible signal that increases in frequency as the unit detects R-134a. Follow the instruction included with the unit in order to properly calibrate the instrument. Use the detector in the proper setting for the type of tested refrigerant.

The most common leaks occur at the refrigerant fittings or connections. The leaks may be the result of any of the following conditions

1. Improper torque
2. Damaged O-rings or sealing washers
3. Lack of lubricant on O-rings
4. Dirt or debris across the O-ring or sealing washers

Maintain a proper scan rate in order to successfully use the J 39400-A or any other electronic leak detector. Carefully follow the manufacturer's instructions regarding the following items

1. Calibration
2. Operation
3. Maintenance

In order to test for leaks, complete the following steps

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1. Completely and slowly circle each joint with the probe.
2. Place the tip of the probe as close as possible to the surface, but no more than 6 mm (0.25 in) away. Do not block the probe tip air intake.
3. A leak exists when the audible tone goes from a steady 1-2 clicks per second to a continuous alarm.
4. Frequently adjust the balance knob in order to maintain the rate of 1-2 clicks per second. Use J 39400-A to inspect each hose connection. Use J 39400-A to inspect all the electrical sensors and switches located in the A/C lines. Use J 39400-A to inspect the service ports. If you know that the system has lost the refrigerant charge and you cannot find a leak using J 39400-A , follow the Fluorescent Dye Injection procedure using J 42220 .

A/C Compressor Shaft Seal Leak Detection with J-39400-A

1. Blow compressed air into the following locations for at least 15 seconds: Behind the A/C compressor clutch/pulley In front of the A/C compressor clutch/pulley
2. Wait 1-2 minutes.
3. Probe the area in front of the pulley.
4. Probe the area behind the pulley.
5. A solid alarm from the detector indicates a leak.

Air Conditioning (A/C) System Performance Test

This test measures the operating efficiency of the A/C system under the following conditions.

1. The current ambient air temperature
2. The current relative humidity
3. The high side pressure of the A/C system
4. The low side pressure of the A/C system
5. The temperature of the air being discharged into the passenger compartment

Test Description

The numbers below refer to the step numbers on the diagnostic table.

1. This step determines if the A/C system has at least the minimum refrigerant charge required to operate the system without damage.
2. This step measures the performance of the A/C system.
3. This step is to allow for vehicle variations as well as high ambient air temperatures.

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Eliminating Air Conditioning Odor

Odors may be emitted from the air conditioning system primarily at start up in hot, humid climates. The following conditions may cause the odor

1. Debris is present in the HVAC module.
2. Microbial growth on the evaporator core

When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. To remove odors of this type, the microbial growth must be eliminated. Perform the following procedure

Deodorize the evaporator core using Deodorizing Aerosol Kit.

Perform the following steps in order to deodorize the A/C system

1. Ensure that the plenum that draws outside air into the HVAC module is clear of debris.
2. Disable the A/C compressor clutch operation by disconnecting the clutch coil electrical connector.
3. Dry the evaporator core by performing the following steps: 3.1. Start the engine. 3.2. Select the maximum temperature setting. 3.3. Select the recirculation mode. 3.4. Run the blower motor on high for 10 minutes.
4. Locate an area in the air conditioning duct between the blower motor and the evaporator core downstream of the blower motor.
5. Drill a 3.175 mm (0.125 in) hole where the hole will not interfere with or damage the following components: The blower motor The evaporator core Any other operating part the of system
6. Wear safety goggles and latex gloves in order to perform the following actions: 6.1. Select the maximum blower speed. 6.2. Insert the deodorizer extension tube into the hole to the mark on the extension tube. 6.3. Use short spray bursts and vary the direction of spray for a 2-3 minute period of time.
7. Shut the engine OFF. Allow the vehicle to sit for 3-5 minutes.
8. Seal the 3.175 mm (0.125 in) hole with body sealer or RTV gasket compound.
9. Start the engine.
10. Operate the blower motor on high for 15-20 minutes to dry.
11. Reconnect the A/C compressor clutch coil electrical connector.
12. Verify proper clutch operation.

Refrigerant Recovery and Recharging

Tools Required

1. J 43600 ACR 2000 Air Conditioning Service Center. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. J 45037 A/C Oil Injector. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Note. R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure.

Note. To avoid system damage use only R-134a dedicated tools when servicing the A/C system.

Note. Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result.

Note. R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerant are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing.

The J 43600 is a complete air conditioning service center for R-134a. The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant.

The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system.

The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain.

Refer to the J 43600 ACR 2000 manual for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to REFRIGERANT SYSTEM CAPACITIES for the correct amount.

A/C Refrigerant System Oil Charge Replenishing

If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037 . For the proper quantities of oil to add to the A/C refrigerant system, refer to REFRIGERANT SYSTEM CAPACITIES .

Flushing

Tools Required

1. J 43600 Air 2000 Air Conditioning Service Center. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. J 45268 A/C Flushing Adapter Kit. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. J 41447 R-134A A/C Tracer Dye - Box of 24. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. J 41459 R-134A - A/C Tracer Dye Injector. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. J 42220 Universal 12V Leak Detection Lamp. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Flushing is intended to remove the following

1. Contaminated PAG oil
2. Desiccant, following a desiccant bag failure
3. Overcharge of PAG oil
4. Refrigerant contamination

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1. Recover the refrigerant. Refer to «REFRIGERANT RECOVERY AND RECHARGING»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the orifice tube. Refer to «EXPANSION (ORIFICE) TUBE REPLACEMENT»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__expansion-orifice-tube-replacement) .
3. Connect the A/C lines with the orifice tube removed.
4. Remove the A/C compressor. Refer to «COMPRESSOR REPLACEMENT (3.1L)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-replacement-31l) or «COMPRESSOR REPLACEMENT (3.8L)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-replacement-38l) .
5. Install the J 45268-3 to the A/C compressor hose assembly.
6. Forward flow refrigerant flushing is recommended for contaminated refrigerant or PAG oil. Perform the following procedure: IMPORTANT: The filter inside J 45268 -1 is serviceable. Remove and discard the check valve from the filter. 6.1. Service the filter with AC Delco P/N GF 470, before each flush. Connect the J 45268 -1 flush filter to the suction port of the J 45268 -3 flush adapter. 6.2. Connect the blue hose from the J 43600 to the J 45268 -1 flush filter adapter. 6.3. Connect the red hose from the J 43600 to the J 45268 -3 .
7. Reverse flow refrigerant flushing is recommended for desiccant bag failure only. Perform the following procedure and replace the accumulator when the flush is complete: IMPORTANT: The filter inside J 45268 -1 is serviceable. Remove and discard the check valve from the filter. 7.1. Service the filter with AC Delco P/N GF 470, before each flush. 7.2. Connect the J 45268 -1 flush filter to the discharge port of the J 45268 -3 flush adapter. 7.3. Connect the blue hose from the J 43600 to the J 45268 -1 flush filter adapter. 7.4. Connect the red hose from the J 43600 to the suction port of the J 45268 -3 . IMPORTANT: Close the valve on the external refrigerant tank, before starting the flush process.
8. Flush the A/C system. Follow the instructions supplied with the J 43600.
9. Remove the J 45268 -3 from the A/C compressor hose assembly. IMPORTANT: Flushing will remove all the PAG oil from the A/C system. The A/C system must be replenished with the correct amount of PAG oil.
10. If you will reinstall the removed A/C compressor, perform the following procedure: Remove the A/C compressor drain plug. Drain the PAG oil from the A/C compressor. Rotate the compressor input shaft to assist in draining the PAG oil from the compressor. Install the A/C compressor drain plug. Tighten Tighten the drain plug to 20 N.m (15 lb ft). Add the total system capacity of PAG oil to the A/C compressor. Refer to «REFRIGERANT SYSTEM CAPACITIES»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
11. If you will replace the A/C compressor after flushing the system, perform the following procedure: Determine if the new service compressor is shipped with PAG oil. Refer to the «REFRIGERANT SYSTEM CAPACITIES»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) . If the service compressor is shipped with PAG oil, DO NOT drain the new PAG oil from the compressor. Deduct the amount of PAG oil shipped with the service compressor from the amount of PAG oil listed in the capacities table. Refer to «REFRIGERANT SYSTEM CAPACITIES»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) . Add the calculated amount to the compressor, as needed. If the service compressor is shipped dry, no calculation is required. Add the total system capacity of PAG oil to the compressor. Refer to «REFRIGERANT SYSTEM CAPACITIES»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
12. Install the A/C compressor. Refer to «COMPRESSOR REPLACEMENT (3.1L)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-replacement-31l) or «COMPRESSOR REPLACEMENT (3.8L)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-replacement-38l) .
13. Inspect the orifice tube for debris. Clean or replace as needed.
14. Install the orifice tube. Refer to «EXPANSION (ORIFICE) TUBE REPLACEMENT»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__expansion-orifice-tube-replacement) .
15. Evacuate and recharge the A/C system. Refer to «REFRIGERANT RECOVERY AND RECHARGING»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) . IMPORTANT: Flushing will remove the fluorescent leak detection dye from the A/C system.
16. Add one bottle of J 41447 using the J 41459 .
17. Leak test the fittings using the J 42220 .

Draining Procedure

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1. Remove the compressor crankcase oil drain plug and drain the crankcase into a clean, graduated container.
2. Drain the oil from both the suction and discharge ports of the removed compressor into the same container. Rotate the compressor shaft to assist in draining the compressor.
3. Measure and record the amount of oil drained from the removed compressor. This measurement will be used during installation of the replacement compressor.
4. Properly discard the used refrigerant oil.

Balancing Procedure

Follow the balancing instructions provided with the compressor.

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1. The replacement compressor is shipped without refrigerant oil.
2. Calculate the amount of refrigerant oil required for oil balancing. Compare the following refrigerant oil capacities: The amount drained and recorded during compressor removal. The amount recommended for component replacement. Refer to «REFRIGERANT SYSTEM CAPACITIES»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Add the greater amount of refrigerant oil to the A/C compressor.

Compressor Replacement (3.1L)

Tools Required

J 39400-A Halogen Leak Detector. See Special Tools and Equipment .

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1. Recover the refrigerant. Refer to «REFRIGERANT RECOVERY AND RECHARGING»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Release the drive belt tension by lifting or rotating the drive belt tensioner with a breaker bar.
3. Remove the drive belt from the A/C compressor pulley and position the drive belt aside.
4. Slowly release the tension from the drive belt tensioner and remove the breaker bar.
5. Raise and support the vehicle. Refer to «JACKING AND LIFTING THE VEHICLE»(/buick/century/vi-1997-2005/remont/hoistjack/#jacking-and-lifting) in General Information.
6. Remove the lower air deflector. Refer to RADIATOR AIR BAFFLE AND DEFLECTOR REPLACEMENT - LOWER in Engine Cooling.
7. Remove the right side engine splash shield. Refer to «SPLASH SHIELD REPLACEMENT -- ENGINE»(/buick/century/vi-1997-2005/remont/exterior-body-panels/#body-front-end) in Body Front End.
8. Remove the A/C compressor hose bolt.
9. Disconnect the A/C compressor hose bolt.
10. Disconnect the A/C compressor hose from the A/C compressor.
11. Remove and discard the sealing washers.
12. Disconnect the electrical connector from the A/C compressor.
13. Remove the lower A/C compressor mounting bolts.
14. Remove the upper A/C compressor mounting bolts.
15. Remove the A/C compressor. IMPORTANT: Replacement compressors are shipped without PAG oil
16. If replacing the compressor, balance the compressor oil. Refer to «COMPRESSOR OIL BALANCING»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Installation Procedure

Note. Refer to FASTENER NOTICE in Cautions and Notices.

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1. Install the compressor drain plug (1). Tighten Tighten the drain plug to 20 N.m (15 lb ft).
2. Install the A/C compressor.
3. Install the A/C compressor upper mounting bolts. Tighten Tighten the bolts to 50 N.m (37 lb ft).
4. Install the A/C compressor lower mounting bolts. Tighten Tighten the bolts to 30 N.m (22 lb ft).
5. Install the new sealing washers. Refer to «SEALING WASHER REPLACEMENT»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
6. Install the A/C compressor hose assembly to the A/C compressor.
7. Install the A/C compressor hose nut to the compressor. Tighten Tighten the nut to 33 N.m (24 lb ft).
8. Connect the electrical connector to the A/C compressor.
9. Install the lower air deflector. Refer to RADIATOR AIR BAFFLE AND DEFLECTOR REPLACEMENT - LOWER in Engine Cooling.
10. Install the right side engine splash shield. Refer to SPLASH SHIELD REPLACEMENT - ENGINE in Body Front End.
11. Lower the vehicle.
12. Release the drive belt tension by lifting or rotating the drive belt tensioner with a breaker bar.
13. Install the drive belt around the A/C compressor pulley. IMPORTANT: Make sure the drive belt is aligned into the proper grooves of all pulleys.
14. Slowly release the tension from the drive belt tensioner and remove the breaker bar.
15. Evacuate and recharge the A/C system. Refer to «REFRIGERANT RECOVERY AND RECHARGING»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
16. Leak test the fittings of the component using J 39400-A .

Compressor Replacement (3.8L)

Tools Required

J 39400-A Halogen Leak Detector. See Special Tools and Equipment .

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1. Recover the refrigerant. Refer to «REFRIGERANT RECOVERY AND RECHARGING»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) IMPORTANT: The supercharged L67 engine utilizes two drive belts. The outer drive belt drives the supercharger. Only release the drive belt tension from the accessories drive belt tensioner.
2. Release the drive belt tension by lifting or rotating the drive belt tensioner with a breaker bar.
3. Remove the drive belt from the A/C compressor pulley and position the drive belt aside.
4. Slowly release the tension from the drive belt tensioner and remove the breaker bar.
5. Raise and support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(/buick/century/vi-1997-2005/remont/hoistjack/#jacking-and-lifting__lifting-and-jacking-the-vehicle) in General Information.
6. Remove the lower air deflector. Refer to RADIATOR AIR BAFFLE AND DEFLECTOR REPLACEMENT - LOWER in Engine Cooling.
7. Remove the right side engine splash shield. Refer to SPLASH SHIELD REPLACEMENT - ENGINE in Body Front End.
8. Remove the A/C compressor hose bolt.
9. Disconnect the A/C compressor hose from A/C compressor.
10. Disconnect the electrical connector from the A/C compressor.
11. Remove and discard the sealing washers.
12. Remove the A/C compressor rear mounting bolts.
13. Remove the A/C compressor front mounting nuts.
14. Remove the A/C compressor. IMPORTANT: Replacement compressors are shipped without PAG oil.
15. If replacing the compressor, balance the compressor oil. Refer to «COMPRESSOR OIL BALANCING»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Note. Refer to FASTENER NOTICE in Cautions and Notices.

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1. Install the compressor drain plug (1). Tighten Tighten the drain plug to 20 N.m (15 lb ft).
2. Install the A/C compressor.
3. Install the A/C compressor front nuts. Tighten Tighten the nuts to 50 N.m (37 lb ft).
4. Install the A/C compressor rear bolts. Tighten Tighten bolts to 50 N.m (37 lb ft).
5. Install the new sealing washers. Refer to «SEALING WASHER REPLACEMENT»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
6. Install the A/C compressor hose assembly to the rear of the A/C compressor.
7. Install the A/C compressor hose nut to the compressor. Tighten Tighten the nut to 33 N.m (24 lb ft).
8. Connect the electrical connector to the A/C compressor.
9. Install the lower air deflector. Refer to RADIATOR AIR BAFFLE AND DEFLECTOR REPLACEMENT - LOWER in Engine Cooling.
10. Install the right side engine splash shield. Refer to SPLASH SHIELD REPLACEMENT - ENGINE in Body Front End.
11. Lower the vehicle.
12. Release the drive belt tension by lifting or rotating the drive belt tensioner with a breaker bar.
13. Install the drive belt around the A/C compressor pulley. IMPORTANT: Make sure the drive belt is aligned into the proper grooves of all pulleys.
14. Slowly release the tension from the drive belt tensioner and remove the breaker bar.
15. Evacuate and recharge the A/C system. Refer to «REFRIGERANT RECOVERY AND RECHARGING»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
16. Leak test the fittings of the component using J 39400-A .

Compressor Clutch Plate and Hub Assembly Removal (V5 - Direct Mount)

Tools Required

1. J 33027-A Clutch Hub Holding Tool. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. J 33013-B Hub and Drive Plate Remover/Installer. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. J 41790 Compressor Holding Fixture. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Scheme 36

Scheme 37

1. Clamp the J 41790 in a vise and attach the A/C compressor to the holding fixture.
2. Hold the clutch hub and drive plate assembly (2) in place using the J 33027-A .
3. Remove the A/C compressor shaft nut with a 13 mm socket (1).
4. Thread the clutch plate and hub remover and installer tool hub and drive plate installer into the hub.
5. Remove the hub and drive plate assembly (1) by turning the center screw into the body of the hub and drive plate installer and against the A/C compressor shaft.
6. Remove the shaft key and retain for reassembly.

Compressor Clutch Plate and Hub Assembly Removal (V5 - Conventional Mount)

Tools Required

1. J 33022 6-Point 13 mm Socket. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. J 33027-A Clutch Hub Holding Tool. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. J 33013-B Hub And Drive Plate Remover/Installer. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. J 34992 Compressor Holding Fixture. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Scheme 38

Scheme 39

1. Clamp the J 34992 in a vise.
2. Attach the A/C compressor to the holding fixture using the thumb screws.
3. Use the J 33027-A in order to prevent the clutch hub and drive plate assembly from turning.
4. Use the J 33022 in order to remove the shaft nut.
5. Thread the J 33013-B into the hub.
6. Use a wrench in order to hold the body of the J 33013-B .
7. Turn the center screw into the body of the J 33013-B in order to remove the clutch plate and hub assembly.
8. Remove the shaft key. Retain the shaft key for reassembly.

Clutch Rotor and/or Bearing Removal (V5 - Direct Mount)

Tools Required

1. J 41790 Compressor Holding Fixture. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. J 41552 Compressor Pulley Puller. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. J 33023-A Puller Pilot. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Scheme 40

Scheme 41

Scheme 42

Scheme 43

1. Install the compressor onto the J 41790 .
2. Remove the clutch plate and hub assembly (2).
3. Remove the clutch rotor and bearing assembly retaining ring (3), using external snap ring pliers (1).
4. Place the J 33023-A on the clutch rotor.
5. Install the J 41552 down into the inner circle of slots in the rotor. Turn the compressor pulley puller clockwise in the slots to engage the puller tangs with the rotor.
6. Hold the compressor pulley puller in place and use a wrench to turn the center forcing screw against the puller pilot to remove the clutch rotor and bearing assembly.

Clutch Rotor and/or Bearing Removal (V5 - Conventional Mount)

Tools Required

1. J 6083 Snap Ring Pliers #24 External. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. J 9398 Rotor Bearing Remover. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. J 8092 Driver Handle. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. J 33020 Pulley Puller. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. J 33023-A Puller Pilot. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Scheme 44

Scheme 45

Scheme 46

Scheme 47

1. Remove the clutch plate and hub assembly. Refer to «COMPRESSOR CLUTCH PLATE AND HUB ASSEMBLY REMOVAL (V5 - DIRECT MOUNT)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-clutch-plate-and-hub-assembly) or «COMPRESSOR CLUTCH PLATE AND HUB ASSEMBLY REMOVAL (V5 - CONVENTIONAL MOUNT)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-clutch-plate-and-hub-assembly) .
2. Use the J 6083 in order to remove the rotor and bearing assembly retaining ring.
3. Install the J 33023-A to the front head.
4. Install the J 33020 into the inner circle of slots in the rotor.
5. Turn the J 33020 clockwise in the slots in order to engage the tangs of the puller with the segments between the slots in the rotor.
6. Hold the J 33020 in place. Tighten the puller screw against the puller guide in order to remove the puller guide in order to remove the puller rotor and bearing assembly.
7. Support the rotor hub in order to prevent damage to the pulley rotor during bearing removal. 7.1. Remove the forcing screw from the J 33020 . 7.2. With the tangs of the J 33020 still engaged in the rotor slots, invert the assembly onto a solid, flat surface or blocks. NOTE: It is not necessary to remove the staking in front of the bearing to remove the bearing, however, it will be necessary to file away the old stake metal for proper clearance for the new bearing to be installed into the rotor bore or the bearing may be damaged.
8. Use a J 9398 with the J 8092 in order to drive the bearing out of the rotor hub.

Compressor Clutch Coil Removal (V5 - Direct Mount)

Tools Required

1. J 41790 Compressor Holding Fixture. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. J 8433 Compressor Pulley Puller. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. J 8433-3 Forcing Screw. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. J 33025 Clutch Coil Puller Legs. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. J 33023-A Puller Pilot. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Scheme 48

Scheme 49

Scheme 50

1. Install the compressor onto the J 41790 .
2. Install the J 33023-A onto the front head of the compressor.
3. Remove the «COMPRESSOR CLUTCH PLATE AND HUB ASSEMBLY REMOVAL (V5 - DIRECT MOUNT)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-clutch-plate-and-hub-assembly) or «COMPRESSOR CLUTCH PLATE AND HUB ASSEMBLY REMOVAL (V5 - CONVENTIONAL MOUNT)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-clutch-plate-and-hub-assembly) .
4. Remove the compressor rotor and bearing assembly. Refer to «CLUTCH ROTOR AND/OR BEARING REMOVAL (V5 - DIRECT MOUNT)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__clutch-rotor-andor-bearing-removal-v5) or «CLUTCH ROTOR AND/OR BEARING REMOVAL (V5 - CONVENTIONAL MOUNT)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__clutch-rotor-andor-bearing-removal-v5) .
5. Mark the clutch coil terminal location (2) on the compressor front head.
6. Install the J 33025 onto the J 8433 .
7. Install the J 8433 onto the compressor clutch coil (1) and tighten the puller leg bolts.
8. Tighten the center forcing screw J 8433-3 of the compressor pulley puller J 8433 against the puller pilot to remove the compressor clutch coil from the compressor.

Compressor Clutch Coil Removal (V5 - Conventional Mount)

Tools Required

1. J 6083 Snap Ring Pliers #24 External. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. J 8433-1 Puller Bar. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. J 8433-3 Forcing Screw. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. J 33020 Pulley Puller. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. J 33023-A Puller Pilot. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
6. J 33025 Clutch Coil Puller Legs. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Scheme 51

Scheme 52

Scheme 53

Scheme 54

1. Remove the clutch plate and hub assembly. Refer to «COMPRESSOR CLUTCH PLATE AND HUB ASSEMBLY REMOVAL (V5 - DIRECT MOUNT)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-clutch-plate-and-hub-assembly) or «COMPRESSOR CLUTCH PLATE AND HUB ASSEMBLY REMOVAL (V5 - CONVENTIONAL MOUNT)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-clutch-plate-and-hub-assembly) .
2. Use the J 6083 in order to remove the rotor and bearing assembly retaining ring.
3. Install the J 33023-A to the front head.
4. Install the J 33020 into the inner circle of slots in the rotor.
5. Turn the J 33020 clockwise in the slots in order to engage the tangs of the puller with the segments between the slots in the rotor.
6. Hold the J 33020 in place. Tighten the puller screw against the puller guide in order to remove the puller rotor and bearing assembly.
7. Mark the location of the clutch coil terminal (1) on the compressor front head.
8. Install the J 33023-A on the front head of the compressor.
9. Install the J 8433-1 and the J 8433-3 with the J 33025 on the front head of the compressor.
10. Tighten the J 8433-3 against the J 33023-A in order to remove the clutch coil (2).

Compressor Control Valve Assembly Removal (V5 - Direct Mount)

Tools Required

J 41790 Compressor Holding Fixture. See Special Tools and Equipment .

Scheme 55

1. Install the compressor onto the J 41790 .
2. Remove the compressor control valve retaining ring using internal snap ring pliers.
3. Remove the compressor control valve from the compressor.

Compressor Control Valve Assembly Removal (V5 - Conventional Mount)

Tools Required

J 5403 Snap Ring Pliers. See Special Tools and Equipment .

Scheme 56

1. Remove the control valve retaining ring using the J 5403 .
2. Remove the control valve assembly (5).

Compressor Pressure Relief Valve Removal (V5 - Direct Mount)

Tools Required

J 41790 Compressor Holding Fixture. See Special Tools and Equipment .

Scheme 57

1. Install the compressor onto the J 41790 .
2. Remove the pressure relief valve from the rear head of the compressor.

Compressor Pressure Relief Valve Removal (V5 - Conventional Mount)

Tools Required

J 41790 Compressor Holding Fixture. See Special Tools and Equipment .

Scheme 58

1. Install the compressor into the J 41790 .
2. Remove the pressure relief valve (2) from the rear head of the compressor.

Compressor Control Switches Removal (V5 - Conventional Mount)

Tools Required

1. J 5403 Snap Ring Pliers. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. J 9553-01 O-Ring Remover. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. J 39500-B ACR4-Black Shroud. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Scheme 59

1. Recover the refrigerant using the J 39500-B .
2. Disconnect the electrical connector from the switch (3 or 4) in the rear head of the compressor.
3. Remove the switch retaining ring using the J 5403 .
4. Remove the switch (3 or 4) from the compressor. NOTE: If the existing switch will be reinstalled in the compressor, a new O-ring seal must be used and preferably a new retainer should also be used. A new switch kit has the O-ring and retainer ring included.
5. Remove the old O-ring seal from switch cavity using the J 9553-01 .

Compressor Control Valve Assembly Install (V5 - Direct Mount)

Tools Required

J 41790 Compressor Holding Fixture. See Special Tools and Equipment .

Scheme 60

1. Coat the control valve O-rings with clean 525 viscosity refrigeration oil.
2. Push the compressor control valve into the compressor with thumb pressure.
3. Using internal snap ring pliers, install the compressor control valve retaining ring. Ensure that the retaining ring is properly seated in the ring groove.
4. Remove the compressor from the J 41790 .

Compressor Control Valve Assembly Install (V5 - Conventional Mount)

Tools Required

J 5403 Snap Ring Pliers. See Special Tools and Equipment .

Scheme 61

1. Coat the O-ring with 525 viscosity refrigeration oil.
2. Using thumb pressure, push the O-rings in place.
3. Install the valve into the case. IMPORTANT: Ensure that the retaining ring is properly seated in the ring groove.
4. Using the J 5403 , install the valve retaining ring (5) with the high point of the curved sides against the valve housing.
5. Perform a leak test. Refer to «COMPRESSOR LEAK TESTING (V5 DIRECT MOUNT)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-leak-testing-v5-direct-mount) or «COMPRESSOR LEAK TESTING (V5 - CONVENTIONAL MOUNT)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-leak-testing-v5-conventional) .

Compressor Clutch Plate/Hub Assembly Install (V5 - Direct Mount)

Tools Required

1. J 33013-B Hub and Drive Plate Remover/Installer. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. J 33027-A Clutch Hub Holding Tool. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. J 33017 Pulley and Bearing Installer. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. J 41790 Compressor Holding Fixture. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Scheme 62

Scheme 63

Scheme 64

1. Install the shaft key into the hub key groove (4) approximately 3.2 mm (1/8 in) out of the keyway. The shaft key is curved slightly to provide an interference fit in the hub key groove.
2. Clean the surfaces of the clutch plate (1) and the clutch rotor (2) before installing the clutch plate and hub assembly.
3. Align the shaft key with the shaft keyway in the clutch plate and the hub assembly and place onto the compressor shaft (3).
4. Remove the J 33013-B . 4.1. Remove the center screw from the body of the hub and drive plate installer. 4.2. Install the center screw into the opposite end of the hub and drive plate installer.
5. Install the J 33013-B and bearing tools (1) onto the clutch plate (3) and the hub assembly (2). 5.1. Back the body of the hub and drive plate installer tool off enough to allow the center screw to be threaded onto the compressor shaft. 5.2. Thread the center screw several turns onto the end of the compressor shaft. Do not tighten the center screw on the compressor shaft.
6. Hold the center screw with a wrench. 6.1. Tighten the hex portion of the hub and drive plate installer body several turns. 6.2. Remove the hub and drive plate installer from the clutch plate and hub. 6.3. Make sure that the shaft key is still in place in the keyway.
7. Reinstall the J 33013-B .
8. Place a feeler gage between the clutch plate and the clutch rotor.
9. Tighten the hex portion of the hub and drive plate installer until the air gap between the clutch plate and clutch rotor is 0.40 mm (0.015 in). Make sure that the air gap is even all around the clutch plate and hub assembly.
10. Remove the J 33013-B .
11. Hold the clutch plate and hub assembly (2) with the J 33027-A . NOTE: Refer to «FASTENER NOTICE»(/buick/century/vi-1997-2005/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
12. Install the compressor shaft nut. Tighten Tighten the compressor shaft nut to 17 N.m (13 lb ft).
13. Spin the pulley rotor by hand to make sure the rotor is not rubbing against the clutch drive plate.
14. Remove the compressor from the J 41790 .

Compressor Clutch Plate/Hub Assembly Install (V5 - Conventional Mount)

Tools Required

1. J 33013-B Hub and Drive Plate Remover/Installer. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. J 33022 6-Shaft Nut Socket - 13mm. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. J 33027-A Clutch Hub Holding Tool. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. J 34992 Compressor Holding Fixture. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Scheme 65

Scheme 66

1. Install the compressor into the J 34992 .
2. Install the shaft key (4) into the key groove of the clutch plate and hub (1).
3. Allow the key to project 3.2 mm (0.126 in) out of the key groove.
4. The shaft key is curved slightly in order to provide an interference fit in the key groove of the hub.
5. Clean the frictional surfaces of the clutch plate and hub and the clutch pulley rotor (2).
6. Align the shaft key with the shaft keyway (3). NOTE: Do not drive or pound on the clutch hub or the shaft. Internal damage to the compressor may result.
7. Place the clutch plate and hub assembly onto the compressor shaft.
8. Remove the center screw from the J 33013-B .
9. Reverse the body direction of the center screw of the J 33013-B .
10. Install the J 33013-B with the bearing.
11. Back off the body of the J 33013-B in order to allow the center screw to be threaded onto the end of the compressor shaft.
12. Hold the center screw of the J 33013-B with a wrench. NOTE: If the center screw is threaded fully onto the end of the compressor shaft, or if the body of the installer is held and the center screw is rotated, the key will wedge and will break the clutch hub.
13. Tighten the hex portion of the body of the J 33013-B in order to press the hub onto the shaft.
14. Tighten the body of the J 33013-B several turns.
15. Remove the J 33013-B .
16. Verify that the shaft key remains in the keyway before installing the clutch plate and hub assembly to the final position.
17. Ensure that the gap between the frictional surfaces of the clutch plate and the clutch rotor is within 0.40-0.50 mm (0.016-0.020 in).
18. Remove the J 33013-B .
19. Verify that the shaft key is even with or slightly above the clutch hub.
20. Install the shaft nut.
21. Hold the clutch plate and hub assembly with the J 33027-A . NOTE: Refer to «FASTENER NOTICE»(/buick/century/vi-1997-2005/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
22. Tighten the shaft nut against the crankshaft shoulder, using a 17.5 N.m (12.5 lb ft) torque wrench and the J 33022 . Tighten Tighten the nut to 16.5 N.m (12 lb ft).
23. Spin the pulley rotor by hand in order to verify that the rotor does not rub the clutch drive plate.

Clutch Rotor and/or Bearing Install (V5 - Direct Mount)

Tools Required

1. J 33013-B Hub and Drive Plate Remover/Installer. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. J 33017 Pulley and Bearing Installer. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. J 41790 Compressor Holding Fixture. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Scheme 67

Scheme 68

1. Position the clutch rotor and bearing assembly (2) onto the compressor.
2. Position the J 33017 and bearing (1) from the J 33013-B directly over the inner race of the bearing.
3. Place the washer (3) onto the body of J 33013-B .
4. Remove the center screw from the body of the hub and drive plate installer.
5. Install the center screw into the opposite end of the hub and drive plate installer.
6. Back the body of the hub and drive plate installer tool off enough to allow the center screw to be threaded onto the end of the compressor shaft.
7. Thread the center screw several turns onto the end of the compressor shaft. Do not tighten the center screw on the compressor shaft.
8. Hold the center screw with a wrench.
9. Tighten the hex portion of the hub and drive plate installer body several turns.
10. Remove the J 33013-B from the clutch rotor and bearing assembly.
11. Ensure that the clutch rotor and bearing (2) is pressed onto the nose of the compressor far enough to clear the groove for the retaining ring. If the clutch rotor and bearing does not clear the groove, repeat steps 7 , 8 and 9 .
12. Install the clutch rotor and bearing retaining ring (3) using external snap ring pliers (1). Ensure that the chamfer side of the retaining ring is facing up when the retaining ring is being installed.
13. Install the clutch plate and hub assembly.
14. Remove the compressor from the J 41790 .

Clutch Rotor and/or Bearing Install (V5 - Conventional Mount)

Tools Required

1. J 6083 #24 External Snap Ring Pliers. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. J 8092 Driver Handle. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. J 8433-1 Puller Bar. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. J 8433-3 Forcing Screw. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. J 9481-A Bearing Installer. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
6. J 21352-A Support Block. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
7. J 33017 Pulley And Bearing Assembly Installer. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
8. J 33019 Bearing Staking Tool. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
9. J 33023-A Puller Pilot. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
10. J 34992 Compressor Holding Fixture. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Note. Do not support the rotor by resting the pulley rim on flat surface during the bearing installation or the rotor face will be bent.

Scheme 69

Scheme 70

Scheme 71

Scheme 72

Scheme 73

1. Place the pulley rotor on the J 21352-A in order to fully support the rotor hub during the bearing installation.
2. Align the new bearing with the hub bore.
3. Using the J 9481-A and the J 8092 , drive the bearing into the hub.
4. Place the J 33019 and the staking pin in the hub bore.
5. Shift the rotor and bearing assembly on the J 21352-A in order to fully support the hub under the location of the staking pin.
6. Use a heavy-duty rubber band (1) in order to hold the stake pin in the guide of the J 33019 . IMPORTANT: Do not allow a metal stake to contact the outer face of the bearing in order to prevent distortion of the outer race.
7. Using care in order to prevent injury, strike the staking pin of the J 33019 . Properly position the stake pin in the guide after each impact on the pin.
8. Continue to strike the pin of the J 33019 until a stake, similar to the original stake, is formed down to, but not touching, the bearing.
9. Stake three places 120 degrees apart.
10. With the compressor mounted to the J 34992 , position the rotor and bearing assembly on the front head.
11. Position the J 33017 and the J 33023-A directly over the inner race of the bearing.
12. Position the J 8433-1 on the J 33023-A .
13. Assemble the two through bolts and the washers of the J 34992 through the slots of the J 8433-1 .
14. Thread the two through bolts into the J 34992 . Ensure that the thread of the through bolts engages the full thickness of the J 34992 .
15. Tighten the J 8433-3 in the J 8433-1 in order to force the pulley rotor and bearing assembly onto the front head of the compressor.
16. If the J 33017 slips off direct, in-line contact with inner face of the bearing, use the following steps: 16.1. Loosen the J 8433-3 . 16.2. Realign the J 33017 and the J 33023-A in order to ensure that the installer clears the front head.
17. Install the rotor and bearing assembly retainer ring using the J 6083 .
18. Install the clutch plate and hub assembly. Refer to «COMPRESSOR CLUTCH PLATE AND HUB ASSEMBLY REMOVAL (V5 - DIRECT MOUNT)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-clutch-plate-and-hub-assembly) or «COMPRESSOR CLUTCH PLATE AND HUB ASSEMBLY REMOVAL (V5 - CONVENTIONAL MOUNT)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-clutch-plate-and-hub-assembly) .

Compressor Clutch Coil Install (V5 - Direct Mount)

Tools Required

1. J 33024 Clutch Coil Installer Adaptor. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. J 33025 Clutch Coil Puller Legs. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. J 8433 Compressor Pulley Puller. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. J 8433-3 Forcing Screw. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. J 41790 Compressor Holding Fixture. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Scheme 74

1. Place the clutch coil assembly (1) on the front head with the clutch coil terminal at the positioned at the mark made during disassembly.
2. Place the J 33024 over the internal opening of the clutch coil housing and align installer with the compressor front head.
3. Install the J 8433-3 into the J 8433 and center the screw in the countersunk center hole of the J 33024 .
4. Install the 4 inch through bolts and washers from the J 42136 tool kit into the J 33025 and attach them to the compressor mounting bosses.
5. Turn the center forcing screw of the J 8433 to press the clutch coil onto the front head until the clutch coil is fully seated. Make sure the clutch coil and the J 33024 stay in-line with each other while pressing the clutch coil onto the compressor.
6. Install the compressor clutch rotor and bearing assembly. Refer to «CLUTCH ROTOR AND/OR BEARING INSTALL (V5 - DIRECT MOUNT)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__clutch-rotor-andor-bearing-install-v5) or «CLUTCH ROTOR AND/OR BEARING INSTALL (V5 - CONVENTIONAL MOUNT)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__clutch-rotor-andor-bearing-install-v5) .
7. Install the compressor clutch plate and hub assembly. Refer to «COMPRESSOR CLUTCH PLATE/HUB ASSEMBLY INSTALL (V5 - DIRECT MOUNT)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-clutch-platehub-assembly-install-v5) or «COMPRESSOR CLUTCH PLATE/HUB ASSEMBLY INSTALL (V5 - CONVENTIONAL MOUNT)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-clutch-platehub-assembly-install-v5) .
8. Remove the compressor from the J 41790 .

Compressor Clutch Coil Install (V5 - Conventional Mount)

Tools Required

1. J 8433-1 Puller Bar. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. J 8433-3 Forcing Screw. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. J 33024 Clutch Coil Installer. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. J 34992 Compressor Holding Fixture. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. J 33025 Clutch Coil Puller Legs. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Scheme 75

Scheme 76

Scheme 77

Scheme 78

Scheme 79

1. Place the clutch coil assembly on the front head with the terminals positioned at the marked location.
2. Place the J 33024 over the internal opening of the clutch coil housing.
3. Align the J 33024 with the compressor front head.
4. Center the J 8433-1 on the countersunk center hole of the J 33024 .
5. Install the through bolts and the washers of the J 34992 through the slots in the J 8433-1 .
6. Thread the through bolts into the J 33025 in order to achieve full fixture thickness. IMPORTANT: Ensure that the clutch coil and the J 33024 stay in-line during the installation.
7. Turn the J 8433-3 of the J 8433-1 in order to force the clutch coil onto the head.
8. With the compressor still mounted to the J 34992 and the coil seated on the front head, stake the front head using a drift punch with a diameter of 3.175 mm (0.125 in).
9. Stake the front head at 3 places 120 degrees apart in order to ensure that the clutch coil remains in position.
10. Ensure that the stake size is only one half of the area of the punch tip and only 0.28-0.35 mm (0.010-0. 015 in) in depth.
11. With the compressor mounted to the J 34992 , position the rotor and bearing assembly on the front head.
12. Position the J 33017 and the J 33023-A directly over the inner race of the bearing.
13. Position the J 8433-1 on the J 33023-A .
14. Assemble the 2 through bolts and the washers of the J 34992 through the slots of the J 8433-1 .
15. Thread the 2 through bolts into the J 34992 . Ensure that the thread of the through bolts engages the full thickness of the J 34992 .
16. Tighten the J 8433-3 in the J 8433-1 in order to force the pulley rotor and bearing assembly onto the front head of the compressor.
17. If the J 33017 slips off direct, in-line contact with inner face of the bearing, use the following steps: 17.1. Loosen the J 8433-3 . 17.2. Realign the J 33017 and the J 33023-A in order to ensure that the installer clears the front head.
18. Install the rotor and bearing assembly retainer ring using the J 6083 .
19. Install the clutch plate and hub assembly. Refer to «COMPRESSOR CLUTCH PLATE AND HUB ASSEMBLY REMOVAL (V5 - DIRECT MOUNT)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-clutch-plate-and-hub-assembly) or «COMPRESSOR CLUTCH PLATE AND HUB ASSEMBLY REMOVAL (V5 - CONVENTIONAL MOUNT)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-clutch-plate-and-hub-assembly) .
20. Install the shaft nut.

Compressor Pressure Relief Valve Install (V5 - Direct Mount)

Tools Required

J 41790 Compressor Holding Fixture. See Special Tools and Equipment .

Scheme 80

1. Clean the pressure relief valve seat area of the rear head.
2. Lubricate the O-ring of the new pressure relief valve with clean 525 viscosity refrigerant oil. NOTE: Refer to «FASTENER NOTICE»(/buick/century/vi-1997-2005/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
3. Install the new pressure relief valve into the compressor. Tighten Tighten the pressure relief valve to 9 N.m (80 lb in).
4. Remove the compressor from the J 41790 .

Scheme 81

1. Clean the valve seat area on the rear head.
2. Lubricate the O-ring of the new pressure relief valve and the O-ring assembly using new 525 viscosity refrigerant oil. NOTE: Refer to «FASTENER NOTICE»(/buick/century/vi-1997-2005/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
3. Install the new pressure relief valve (2). Tighten Tighten the valve to 9 N.m (80 lb in).
4. Perform a leak test. Refer to «COMPRESSOR LEAK TESTING (V5 DIRECT MOUNT)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-leak-testing-v5-direct-mount) or «COMPRESSOR LEAK TESTING (V5 - CONVENTIONAL MOUNT)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-leak-testing-v5-conventional) .

Compressor Control Switches Install (V5 - Conventional Mount)

Tools Required

J 5403 Snap Ring Pliers. See Special Tools and Equipment .

Scheme 82

1. Inspect the switch cavity and the O-ring groove in the rear head for dirt or foreign material. Clean the cavity and groove as necessary.
2. Coat the new O-ring using clean 525 viscosity refrigerant oil.
3. Install the O-ring into the groove in the switch cavity.
4. Lubricate the switch housing using clean 525 viscosity refrigerant oil.
5. Carefully insert the switch (3 or 4) into the switch cavity until the switch bottoms in the cavity.
6. Using the J 5403 , install the switch retaining ring with the high point of the curved sides adjacent to the switch housing.
7. Ensure that the retaining ring is seated in the retaining ring groove in the switch cavity.
8. Evacuate and recharge the system.
9. Perform a leak test. Refer to «COMPRESSOR LEAK TESTING (V5 DIRECT MOUNT)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-leak-testing-v5-direct-mount) or «COMPRESSOR LEAK TESTING (V5 - CONVENTIONAL MOUNT)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-leak-testing-v5-conventional) .

Compressor Leak Testing (V5 Direct Mount)

Tools Required

1. J 39400-A Halogen Leak Detector. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. J 43600 ACR 2000 Air Conditioning Service Center. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. J 39893 Pressure Test Adapter. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Scheme 83

1. With the sealing washers in place, install the J 39893 on the rear head of the compressor.
2. Connect the gage charging lines and the J 43600 .
3. Pressurize the suction and the high-side of the compressor with R-134a refrigerant.
4. With the compressor in a horizontal position, rotate by hand the compressor shaft in the operating direction.
5. Rotate the shaft several times.
6. Using the J 39400-A , check for leaks at the following locations: Pressure relief valve Rear head switch Front head seals Rear head seals Through bolt head gaskets Compressor shaft seal
7. Perform the measures necessary to correct any external leaks found.
8. Recheck for leaks following any repair.
9. Recover the refrigerant.
10. Disconnect the hoses from the J 39893 .
11. Remove the J 39893 .

Compressor Leak Testing (V5 - Conventional Mount)

Tools Required

1. J 39400-A Halogen Leak Detector. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. J 43600 ACR 2000 Air Conditioning Service Center. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. J 39893 Pressure Test Adapter. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Scheme 84

1. With the sealing washers in place, install the J 39893 on the rear head of the compressor.
2. Connect the gage charging lines and the J 43600 .
3. Pressurize the suction and the high-side of the compressor using R-134a refrigerant.
4. With the compressor in a horizontal position, rotate the compressor shaft several turns by hand in the operating direction.
5. Using the J 39400-A , inspect for leaks at the following locations: The pressure relief valve The rear head switch The front head seal The through bolt head gaskets The compressor shaft seal
6. Perform the measures necessary to correct any external leaks found.
7. Inspect for leaks again following any repair.
8. Recover the refrigerant.
9. Disconnect the hoses from the J 39893 .
10. Remove the J 39893 .

Removal Procedure

Tools Required

1. J 41790 Compressor Holding Fixture. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. J 41552 Compressor Pulley Puller. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. J 33023-A Puller Pilot. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. J 33013-B Hub and Drive Plate Remover/Installer. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. J 33017 Pulley and Bearing Installer. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Scheme 85

Scheme 86

Scheme 87

Scheme 88

1. Remove the A/C compressor. Refer to «COMPRESSOR REPLACEMENT (3.1L)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-replacement-31l) or «COMPRESSOR REPLACEMENT (3.8L)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-replacement-38l) .
2. Install the compressor onto the J 41790 .
3. Remove the clutch plate and hub assembly (2).
4. Remove the clutch rotor and bearing assembly retaining ring (3), using external snap ring pliers (1).
5. Place the J 33023-A on the clutch rotor.
6. Install the J 41552 down into the inner circle of slots in the rotor. Turn the compressor pulley puller clockwise in the slots to engage the puller tangs with the rotor.
7. Hold the compressor pulley puller in place and use a wrench to turn the center forcing screw against the puller pilot to remove the clutch rotor and bearing assembly.

Scheme 89

Scheme 90

1. Position the clutch rotor and bearing assembly (2) onto the compressor.
2. Position the J 33017 and bearing (1) from the J 33013-B directly over the inner race of the bearing.
3. Place the washer (3) onto the body of J 33013-B .
4. Remove the center screw from the body of the hub and drive plate installer.
5. Install the center screw into the opposite end of the hub and drive plate installer.
6. Back the body of the hub and drive plate installer tool off enough to allow the center screw to be threaded onto the end of the compressor shaft.
7. Thread the center screw several turns onto the end of the compressor shaft. Do not tighten the center screw on the compressor shaft.
8. Hold the center screw with a wrench.
9. Tighten the hex portion of the hub and drive plate installer body several turns.
10. Remove the J 33013-B from the clutch rotor and bearing assembly.
11. Ensure that the clutch rotor and bearing (2) is pressed onto the nose of the compressor far enough to clear the groove for the retaining ring. If the clutch rotor and bearing does not clear the groove, repeat steps 7 , 8 and 9 .
12. Install the clutch rotor and bearing retaining ring (3) using external snap ring pliers (1). Ensure that the chamfer side of the retaining ring is facing up when the retaining ring is being installed.
13. Install the clutch plate and hub assembly.
14. Remove the compressor from the J 41790 .
15. Install the A/C compressor. Refer to «COMPRESSOR REPLACEMENT (3.1L)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-replacement-31l) or «COMPRESSOR REPLACEMENT (3.8L)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-replacement-38l) .

Clutch Rotor and/or Bearing Replacement (V-5 Conventional Mount)

Tools Required

1. J 6083 External Snap Ring Pliers. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. J 8092 Universal Driver Handle. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. J 8433-1 Puller Bar. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. J 8433-3 Forcing Screw. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. J 9398 Rotor Bearing Remover. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
6. J 9481-A Bearing Installer. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
7. J 21352-A Support Block. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
8. J 33017 Pulley and Bearing Installer. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
9. J 33019 Pulley Bearing Staking Tool. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
10. J 33023-A Puller Pilot. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
11. J 34992 Compressor Holding Fixture. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
12. J 33020 Pulley Puller. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Scheme 91

Scheme 92

Scheme 93

Scheme 94

1. Remove the A/C compressor. Refer to «COMPRESSOR REPLACEMENT (3.1L)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-replacement-31l) or «COMPRESSOR REPLACEMENT (3.8L)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-replacement-38l) .
2. Remove the clutch plate and hub assembly. Refer to «COMPRESSOR CLUTCH PLATE AND HUB ASSEMBLY REMOVAL (V5 - DIRECT MOUNT)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-clutch-plate-and-hub-assembly) or «COMPRESSOR CLUTCH PLATE AND HUB ASSEMBLY REMOVAL (V5 - CONVENTIONAL MOUNT)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-clutch-plate-and-hub-assembly) .
3. Use the J 6083 in order to remove the rotor and bearing assembly retaining ring.
4. Install the J 33023-A to the front head.
5. Install the J 33020 into the inner circle of slots in the rotor.
6. Turn the J 33020 clockwise in the slots in order to engage the tangs of the puller with the segments between the slots in the rotor.
7. Hold the J 33020 in place. Tighten the puller screw against the puller guide in order to remove the puller rotor and bearing assembly.
8. Support the rotor hub in order to prevent damage to the pulley rotor during bearing removal. 8.1. Remove the forcing screw from the J 33020 . 8.2. With the tangs of the J 33020 still engaged in the rotor slots, invert the assembly onto a solid, flat surface or blocks. NOTE: It is not necessary to remove the staking in front of the bearing to remove the bearing, however, it will be necessary to file away the old stake metal for proper clearance for the new bearing to be installed into the rotor bore or the bearing may be damaged.
9. Use a J 9398 with the J 8092 in order to drive the bearing out of the rotor hub.

Note. Do not support the rotor by resting the pulley rim on a flat surface during the bearing installation or the rotor face will be bent.

Scheme 95

Scheme 96

Scheme 97

Scheme 98

1. Place the pulley rotor on the J 21352-A in order to fully support the rotor hub during the bearing installation.
2. Align the new bearing with the hub bore.
3. Using the J 9481-A and the J 8092 , drive the bearing into the hub. The J 9481-A applies force to the outer race of the bearing.
4. Place the J 33019 and the staking pin in the hub bore.
5. Shift the rotor and bearing assembly on the J 21352-A in order to fully support the hub under the location of the staking pin.
6. Use a heavy-duty rubber band (1) in order to hold the stake pin in the guide of the J 33019 . IMPORTANT: Do not allow a metal stake to contact the outer face of the bearing in order to prevent distortion of the outer race.
7. Using care in order to prevent injury, strike the staking pin of the J 33019 . Properly position the stake pin in the guide after each impact on the pin.
8. Continue to strike the pin of the J 33019 until a stake, similar to the original stake, is formed down to, but not touching, the bearing.
9. Stake 3 places 120 degrees apart.
10. With the compressor mounted to the J 34992 , position the rotor and bearing assembly on the front head.
11. Position the J 33017 and the J 33023-A directly over the inner race of the bearing.
12. Position the J 8433-1 on the J 33023-A .
13. Assemble the 2 through bolts and the washers of the J 34992 through the slots of the J 8433-1 .
14. Thread the 2 through bolts into the J 34992 . Ensure that the thread of the through bolts engages the full thickness of the J 34992 .
15. Tighten the J 8433-3 in the J 8433-1 in order to force the pulley rotor and bearing assembly onto the front head of the compressor.
16. If the J 33017 slips off direct, in-line contact with inner face of the bearing, use the following steps: 16.1. Loosen the J 8433-3 . 16.2. Realign the J 33017 and the J 33023-A in order to ensure that the installer clears the front head.
17. Install the rotor and bearing assembly retainer ring using the J 6083 .
18. Install the clutch plate and hub assembly. Refer to «COMPRESSOR CLUTCH PLATE/HUB ASSEMBLY INSTALL (V5 - DIRECT MOUNT)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-clutch-platehub-assembly-install-v5) or «COMPRESSOR CLUTCH PLATE/HUB ASSEMBLY INSTALL (V5 - CONVENTIONAL MOUNT)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-clutch-platehub-assembly-install-v5) .
19. Install the A/C compressor. Refer to «COMPRESSOR REPLACEMENT (3.1L)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-replacement-31l) or «COMPRESSOR REPLACEMENT (3.8L)»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-replacement-38l) .

Scheme 99

1. Remove the seal washer from the A/C refrigerant component. IMPORTANT: Cap or tape the open A/C refrigerant components immediately to prevent system contamination.
2. Inspect the seal washer for signs of damage to help determine the root cause of the failure.
3. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. IMPORTANT: DO NOT reuse sealing washer.
4. Discard the sealing washer.

Scheme 100

1. Inspect the new seal washer for any signs of cracks, cuts, or damage. Do not use a damaged seal washer.
2. Remove the cap or tape from the A/C refrigerant components.
3. Using a lint-free clean, dry cloth, clean the sealing surfaces of the A/C refrigerant components.
4. Carefully install the new seal washer onto the A/C refrigerant component. The washer must completely bottom against the surface of the fitting. IMPORTANT: After tightening the A/C components, there should be a slight sealing washer gap of approximately 1.2 mm (3/64 in) between the A/C line and the A/C component.
5. Assemble the remaining A/C refrigerant components. Refer to the appropriate repair procedure.

Scheme 101

1. Disassemble the A/C refrigerant components. Refer to the appropriate repair procedure For compression style fittings use a back up wrench on the fitting (2) and loosen the fitting nut (1). For banjo style fittings remove the bolt retaining the banjo type fitting.
2. Remove the O-ring seal from the A/C refrigerant component.
3. Inspect the O-ring seal for signs of damage to help determine the root cause of the failure.
4. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. IMPORTANT: Cap or tape the open A/C refrigerant components immediately to prevent system contamination.
5. Cap or tape the A/C refrigerant components.
6. Discard the O-ring seal.

Scheme 102

Scheme 103

1. Inspect the new O-ring seal for any sign or cracks, cuts, or damage. Replace if necessary.
2. Remove the cap or tape from the A/C refrigerant components.
3. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the A/C refrigerant components. IMPORTANT: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new O-ring seal to enter the refrigerant system.
4. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil. IMPORTANT: DO NOT reuse O-ring seals.
5. Carefully slide the new O-ring seal onto the A/C refrigerant component.
6. The O-ring seal must be fully seated.
7. Assemble the A/C components. Refer to the appropriate repair procedure. For compression style fittings use a back up wrench on the fitting (2) and tighten the fitting nut (1) to specification. For banjo style fittings install the bolt retaining the banjo type fitting and tighten to specification.

Compressor Hose Assembly Replacement (3.1L)

Tools Required

J 39400-A Halogen Leak Detector. See Special Tools and Equipment .

Scheme 104

Scheme 105

Scheme 106

1. Recover the refrigerant. Refer to «REFRIGERANT RECOVERY AND RECHARGING»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the left front fender upper diagonal brace. Refer to BRACE REPLACEMENT - FRONT FENDER UPPER DIAGONAL in Body Front End.
3. Remove the air cleaner assembly.
4. Remove the A/C compressor hose nut (1).
5. Disconnect the A/C compressor hose from the condenser.
6. Remove the A/C compressor hose nut (2).
7. Remove the A/C compressor hose from the accumulator.
8. Remove the lower air deflector. Refer to RADIATOR AIR BAFFLE AND DEFLECTOR REPLACEMENT - LOWER in Engine Cooling.
9. Remove the A/C compressor hose assembly nut from the A/C compressor. IMPORTANT: Remove and discard all the used O-ring and sealing washers.
10. Remove the A/C compressor hose from the A/C compressor.

Scheme 107

Scheme 108

Scheme 109

Scheme 110

1. Install the new sealing washers onto the A/C compressor hose assembly. Refer to «SEALING WASHER REPLACEMENT»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Install the A/C compressor hose to the A/C compressor. NOTE: Refer to «FASTENER NOTICE»(/buick/century/vi-1997-2005/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
3. Install the A/C compressor hose nut. Tighten Tighten the nut to 33 N.m (24 lb ft).
4. Install the lower air deflector. Refer to RADIATOR AIR BAFFLE AND DEFLECTOR REPLACEMENT - LOWER in Engine Cooling.
5. Install the new O-ring seal to the A/C compressor hose assembly. Refer to «O-RING REPLACEMENT»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
6. Install the A/C compressor hose to the accumulator.
7. Install the A/C compressor hose nut (2) to the accumulator. Tighten Tighten the nut to 16 N.m (12 lb ft).
8. Install the A/C compressor hose to the condenser.
9. Install the A/C compressor hose nut (1) to the condenser. Tighten Tighten the nut to 16 N.m (12 lb ft).
10. Install the left front fender upper diagonal brace. Refer to BRACE REPLACEMENT - FRONT FENDER UPPER DIAGONAL in Body Front End.
11. Install the air cleaner assembly.
12. Evacuate and recharge the A/C system. Refer to «REFRIGERANT RECOVERY AND RECHARGING»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
13. Leak test the fittings of the component using J 39400-A .

Compressor Hose Assembly Replacement (3.8L)

Tools Required

J 39400-A Halogen Leak Detector. See Special Tools and Equipment .

Scheme 111

Scheme 112

Scheme 113

1. Recover the refrigerant. Refer to «REFRIGERANT RECOVERY AND RECHARGING»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the left front fender upper diagonal brace. Refer to BRACE REPLACEMENT - FRONT FENDER UPPER DIAGONAL in Body Front End.
3. Remove the air cleaner assembly.
4. Remove the A/C compressor hose nut (1).
5. Disconnect the A/C compressor hose from the condenser.
6. Remove the A/C compressor hose nut (2).
7. Remove the A/C compressor hose from the accumulator.
8. Remove the lower air deflector. Refer to RADIATOR AIR BAFFLE AND DEFLECTOR REPLACEMENT - LOWER in Engine Cooling.
9. Remove the A/C compressor hose nut from the A/C compressor. IMPORTANT: Remove and discard all the used O-ring and sealing washers.
10. Remove the A/C compressor hose from the A/C compressor.

Scheme 114

Scheme 115

Scheme 116

Scheme 117

Scheme 118

1. Install new sealing washers onto the A/C compressor hose assembly. Refer to «SEALING WASHER REPLACEMENT»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Install the A/C compressor hose to the A/C compressor. NOTE: Refer to «FASTENER NOTICE»(/buick/century/vi-1997-2005/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
3. Install the A/C compressor hose nut to the A/C compressor. Tighten Tighten the nut to 33 N.m (24 lb ft).
4. Install the lower air deflector. Refer to RADIATOR AIR BAFFLE AND DEFLECTOR REPLACEMENT - LOWER in Engine Cooling.
5. Install the new O-ring seal to the A/C compressor hose assembly. Refer to «O-RING REPLACEMENT»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
6. Install the A/C compressor hose to the accumulator.
7. Install the A/C compressor hose nut (2) to the accumulator. Tighten Tighten the nut to 16 N.m (12 lb ft).
8. Install the A/C compressor hose to the condenser.
9. Install the A/C compressor hose nut to the condenser. Tighten Tighten the nut to 16 N.m (12 lb ft).
10. Install the left front fender upper diagonal brace. Refer to BRACE REPLACEMENT - FRONT FENDER UPPER DIAGONAL in Body Front End.
11. Install the air cleaner assembly.
12. Evacuate and recharge the A/C system. Refer to «REFRIGERANT RECOVERY AND RECHARGING»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
13. Leak test the fittings of the component using J 39400-A .

Condenser Tube Replacement

Tools Required

J 39400-A Halogen Leak Detector. See Special Tools and Equipment .

Scheme 119

Scheme 120

1. Recover the refrigerant. Refer to «REFRIGERANT RECOVERY AND RECHARGING»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the air cleaner assembly.
3. Remove the vacuum brake booster. Refer to «VACUUM BRAKE BOOSTER»(/buick/century/vi-1997-2005/remont/mechanical-hydraulic/#disc-brakes-drum-brakes__vacuum-brake-booster) in Disc & Drum.
4. Remove the lower radiator air baffle. Refer to RADIATOR AIR BAFFLE AND DEFLECTOR REPLACEMENT - LOWER in Engine Cooling.
5. Loosen the condenser tube nut at the condenser.
6. Disconnect the condenser tube from the condenser.
7. Lower the vehicle.
8. Disconnect the electrical connector from the A/C refrigerant pressure sensor.
9. Remove the condenser tube from the support clip.
10. Loosen the evaporator tube nut from the condenser tube
11. Disconnect the evaporator tube from the condenser tube.
12. Remove the condenser tube.
13. Remove the discard the O-ring.
14. Remove the A/C pressure sensor from the condenser tube.

Scheme 121

Scheme 122

1. Install the A/C pressure sensor to the condenser tube.
2. Install the new O-ring onto the condenser tube. Refer to «O-RING REPLACEMENT»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Install the condenser tube to the support clip.
4. Connect the evaporator tube to the condenser tube. NOTE: Refer to «FASTENER NOTICE»(/buick/century/vi-1997-2005/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
5. Tighten the evaporator tube nut. Tighten Tighten the nut to 27 N.m (20 lb ft).
6. Connect the A/C refrigerant pressure sensor electrical connector.
7. Raise and support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(/buick/century/vi-1997-2005/remont/hoistjack/#jacking-and-lifting__lifting-and-jacking-the-vehicle) in General Information.
8. Connect the condenser tube to the condenser.
9. Tighten the condenser tube nut. Tighten Tighten the nut to 27 N.m (20 lb ft).
10. Install the lower radiator air baffle. Refer to RADIATOR AIR BAFFLE AND DEFLECTOR REPLACEMENT - LOWER in Engine Cooling.
11. Install the vacuum brake booster. Refer to «VACUUM BRAKE BOOSTER»(/buick/century/vi-1997-2005/remont/mechanical-hydraulic/#disc-brakes-drum-brakes__vacuum-brake-booster) in Disc & Drum.
12. Install the air cleaner assembly.
13. Evacuate and recharge the A/C system. Refer to «REFRIGERANT RECOVERY AND RECHARGING»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
14. Leak test the fittings of the component using J 39400-A .

Evaporator Tube Replacement

Tools Required

J 39400-A Halogen Leak Detector. See Special Tools and Equipment .

Scheme 123

Scheme 124

1. Recover the refrigerant. Refer to «REFRIGERANT RECOVERY AND RECHARGING»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the air cleaner assembly.
3. Remove the vacuum brake booster. Refer to «VACUUM BRAKE BOOSTER»(/buick/century/vi-1997-2005/remont/mechanical-hydraulic/#disc-brakes-drum-brakes__vacuum-brake-booster) in Disc & Drum.
4. Remove the condenser tube from the support clip.
5. Disconnect the evaporator tube nut from the condenser tube.
6. Disconnect the evaporator tube from the condenser tube.
7. Remove the accumulator tube block fitting bolt from the evaporator.
8. Disconnect the evaporator tube from the evaporator.
9. Remove the O-ring and discard.

Scheme 125

Scheme 126

1. Install the new O-ring seals on to the evaporator tube. Refer to «O-RING REPLACEMENT»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Connect the evaporator inlet tube to the condenser tube.
3. Connect the evaporator tube to the evaporator. NOTE: Refer to «FASTENER NOTICE»(/buick/century/vi-1997-2005/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
4. Install the accumulator tube to the evaporator block fitting.
5. Install the accumulator block fitting bolt to the evaporator. Tighten Tighten the bolt to 16 N.m (12 lb ft).
6. Tighten the evaporator tube nut. Tighten Tighten the nut to 27 N.m (20 lb ft).
7. Install the condenser tube to the support clip.
8. Install the vacuum brake booster. Refer to «VACUUM BRAKE BOOSTER»(/buick/century/vi-1997-2005/remont/mechanical-hydraulic/#disc-brakes-drum-brakes__vacuum-brake-booster) in Disc & Drum.
9. Install the air cleaner assembly.
10. Evacuate and recharge the A/C system. Refer to «REFRIGERANT RECOVERY AND RECHARGING»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
11. Leak test the fittings of the component using J 39400-A .

Accumulator Tube Replacement

Tools Required

J 39400-A Halogen Leak Detector. See Special Tools and Equipment .

Scheme 127

Scheme 128

Scheme 129

1. Recover the refrigerant. Refer to «REFRIGERANT RECOVERY AND RECHARGING»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the air cleaner assembly.
3. Remove the vacuum brake booster. Refer to «VACUUM BRAKE BOOSTER»(/buick/century/vi-1997-2005/remont/mechanical-hydraulic/#disc-brakes-drum-brakes__vacuum-brake-booster) in Disc & Drum.
4. Remove the brake pressure modulator valve bracket. Refer to BRAKE PRESSURE MODULATOR VALVE (BPMV) BRACKET REPLACEMENT in Antilock Brake System.
5. Remove the accumulator clip.
6. Loosen the accumulator tube nut at the accumulator (2).
7. Disconnect the accumulator tube from the accumulator.
8. Remove the accumulator tube to evaporator core block fitting bolt.
9. Disconnect the accumulator tube from the evaporator.
10. Remove the accumulator tube.
11. Remove the O-ring seal and discard.

Scheme 130

Scheme 131

Scheme 132

1. Install the new O-ring seal. Refer to «O-RING REPLACEMENT»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Install the accumulator tube.
3. Connect the accumulator tube to the evaporator. NOTE: Refer to «FASTENER NOTICE»(/buick/century/vi-1997-2005/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
4. Install the accumulator tube to evaporator core block fitting bolt. Tighten Tighten the bolt to 16 N.m (12 lb ft).
5. Connect the accumulator tube to the accumulator (2).
6. Tighten the accumulator tube nut at the accumulator. Tighten Tighten the nut to 47 N.m (35 lb ft).
7. Install the accumulator clip.
8. Install the vacuum brake booster bracket. Refer to «VACUUM BRAKE BOOSTER»(/buick/century/vi-1997-2005/remont/mechanical-hydraulic/#disc-brakes-drum-brakes__vacuum-brake-booster) in Disc & Drum.
9. Install the brake pressure modulator valve bracket. Refer to BRAKE PRESSURE MODULATOR VALVE (BPMV) BRACKET REPLACEMENT in Antilock Brake System.
10. Install the air cleaner assembly.
11. Evacuate and recharge the A/C system. Refer to «REFRIGERANT RECOVERY AND RECHARGING»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
12. Leak test the fittings of the component using J 39400-A .

Air Conditioning (A/C) Refrigerant Filter Installation

Tools Required

J 39400-A Halogen Leak Detector. See Special Tools and Equipment .

Scheme 133

1. Recover the refrigerant. Refer to «REFRIGERANT RECOVERY AND RECHARGING»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the evaporator tube from the condenser tube. Refer to «CONDENSER TUBE REPLACEMENT»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__condenser-tube-replacement) . IMPORTANT: Measure from the condenser block fitting end of the condenser tube. Cut the tube with a tubing cutter.
3. Measure 110 mm (4.3 in) and mark the condenser tube. IMPORTANT: Do not allow metal shavings to enter the condenser tube during cutting or when removing the burrs.
4. Cut the condenser tube.
5. Measure 60 mm (2.4 in) and mark the condenser tube.
6. Cut the condenser tube.
7. Remove any burrs from the cut ends of the condenser tube. IMPORTANT: You must first remove the O-ring from the filter before you seat the ferrules to the condenser tube.
8. Remove the O-ring from the A/C refrigerant filter.
9. Install one flare nut and one ferrule to the condenser tube with the tapered end of the ferrule facing the flare nut. NOTE: Refer to «FASTENER NOTICE»(/buick/century/vi-1997-2005/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices. IMPORTANT: Fully seat the A/C refrigerant filter onto the condenser tube.
10. Install the A/C refrigerant filter to the condenser tube with the arrow pointing toward the evaporator. Tighten Tighten the A/C refrigerant filter flare nut to 15 N.m (11 lb ft).
11. Install one flare nut and one ferrule to the other half of the condenser tube with the tapered end of the ferrule facing the flare nut.
12. Install the A/C refrigerant filter to the condenser tube. Tighten Tighten the A/C refrigerant filter flare nut to 15 N.m (11 lb ft).
13. Loosen the flare nuts and remove the A/C refrigerant filter from the condenser tube.
14. Lubricate and install the O-ring to each end of the condenser tube. Refer to «O-RING REPLACEMENT»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) . IMPORTANT: Fully seat the filter to the ferrules in order to ensure that the O-ring seat inside of the filter housing.
15. Install the A/C refrigerant filter to the condenser tube with the arrow pointing toward the evaporator. Tighten Tighten the A/C refrigerant filter flare nuts to 15 N.m (11 lb ft).
16. Install the evaporator tube to the condenser tube. Refer to «CONDENSER TUBE REPLACEMENT»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__condenser-tube-replacement) .
17. Remove the air cleaner assembly.
18. Evacuate and recharge the A/C system. Refer to «REFRIGERANT RECOVERY AND RECHARGING»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
19. Leak test the fittings of the component using J 39400-A .

Air Conditioning (A/C) Refrigerant Filter Replacement

Tools Required

J 39400-A Halogen Leak Detector. See Special Tools and Equipment .

Scheme 134

1. Recover the refrigerant. Refer to «REFRIGERANT RECOVERY AND RECHARGING»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the left front fender upper diagonal brace. Refer to BRACE REPLACEMENT - FRONT FENDER UPPER DIAGONAL in Body Front End.
3. Remove the air cleaner assembly.
4. Loosen the A/C refrigerant filter flare nuts. IMPORTANT: Immediately cap or tape the open ends of the condenser tube in order to prevent contamination.
5. Remove the A/C refrigerant filter from the condenser tube.
6. Discard the O-ring.

Scheme 135

1. Remove the cap or the tap from the ends of the condenser tube.
2. Lubricate and install new O-rings to each end of the condenser tube. Refer to «O-RING REPLACEMENT»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) . NOTE: Refer to «FASTENER NOTICE»(/buick/century/vi-1997-2005/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices. IMPORTANT: Fully seat the A/C filter to the ferrules in order to ensure that the O-ring seat inside the filter housing.
3. Install the A/C refrigerant filter to the condenser tube with the arrow pointing toward the evaporator. Tighten Tighten the A/C refrigerant filter flare nuts to 15 N.m (11 lb ft).
4. Install the air cleaner assembly.
5. Install the left front fender upper diagonal brace. Refer to BRACE REPLACEMENT - FRONT FENDER UPPER DIAGONAL in Body Front End.
6. Evacuate and recharge the A/C system. Refer to «REFRIGERANT RECOVERY AND RECHARGING»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
7. Leak test the fittings of the component using J 39400-A .

Expansion (Orifice) Tube Replacement

Tools Required

J 26549-E Orifice Tube Remover. See Special Tools and Equipment .

Scheme 136

1. Remove the condenser tube. Refer to «CONDENSER TUBE REPLACEMENT»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__condenser-tube-replacement) .
2. Use J 26549-E in order to remove the expansion (orifice) tube. IMPORTANT: DO NOT use any solvents or chemicals to clean the porous plastic inlet filter of the expansion (orifice) tube.
3. Inspect the expansion (orifice) tube for the following conditions and clean or replace with a new tube as indicated: Broken plastic frame (1); replace the tube. Inlet filter (3) damaged or plugged with fine gritty material; replace the tube. Inlet filter (3) coated with metal chips, flakes, or slivers; remove the coating with low pressure shop air ONLY and reuse if the filter is cleaned satisfactorily. Do NOT reuse the O-ring seals (2).

Scheme 137

1. If you reuse the orifice tube, install the new O-ring seals (2).
2. Carefully grasp the edge of the expansion (orifice) tube (1) without touching the inlet filter (3) and insert the expansion tube into the condenser tube until fully seated.
3. Install the condenser tube. Refer to «CONDENSER TUBE REPLACEMENT»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__condenser-tube-replacement) .

Scheme 138

Scheme 139

1. Remove the underhood relay center knob (1).
2. Remove the underhood relay center cover (2).
3. Remove the A/C compressor control relay (15) from the electrical center.

Scheme 140

Scheme 141

1. Install the A/C compressor control relay (15) into the electrical center.
2. Install the underhood relay cover (2).
3. Install the underhood relay center knob (1).

Service Ports Replacement

Tools Required

J 39037 Charge Valve Octagon Socket. See Special Tools and Equipment .

Scheme 142

1. Remove the service port cap.
2. Recover the refrigerant. Refer to «REFRIGERANT RECOVERY AND RECHARGING»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
3. Use the J 39037 to remove the service-port.

Scheme 143

1. Replace the O-ring. Refer to «O-RING REPLACEMENT»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) . NOTE: Refer to «FASTENER NOTICE»(/buick/century/vi-1997-2005/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
2. Install the service port valve. Tighten Tighten the valve to 11 N.m (98 lb in).
3. Evacuate and charge the system. Refer to «REFRIGERANT RECOVERY AND RECHARGING»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
4. Leak test the A/C service port. Refer to «LEAK TESTING»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. Install the service port cap.

Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement

Tools Required

J 39400-A Halogen Leak Detector. See Special Tools and Equipment .

Scheme 144

Scheme 145

1. Remove the air cleaner assembly. .
2. Disconnect the A/C refrigerant pressure sensor from the electrical connector.
3. Remove the A/C refrigerant pressure sensor from the condenser tube.

Scheme 146

Scheme 147

1. Install the new O-ring seal. Refer to «O-RING REPLACEMENT»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) . NOTE: Refer to «FASTENER NOTICE»(/buick/century/vi-1997-2005/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
2. Install the A/C refrigerant pressure sensor to the condenser tube. Tighten Tighten the sensor to 4.7 N.m (41 lb in).
3. Connect the A/C refrigerant pressure sensor to the electrical connector.
4. Install the air cleaner assembly.
5. Leak test the fitting of the component using J 39400-A .

Condenser Replacement

Tools Required

J 39400-A Halogen Leak Detector. See Special Tools and Equipment .

Scheme 148

Scheme 149

Scheme 150

1. Recover the refrigerant. Refer to «REFRIGERANT RECOVERY AND RECHARGING»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the front fender upper diagonal. Refer to BRACE REPLACEMENT - FRONT FENDER UPPER DIAGONAL in Body Front End.
3. Remove the air cleaner assembly.
4. Remove the radiator. Refer to RADIATOR REPLACEMENT in Engine Cooling.
5. Loosen the condenser tube nut from the condenser.
6. Disconnect the condenser tube from the condenser.
7. Remove the A/C compressor hose block fitting nut from the condenser.
8. Disconnect the A/C compressor hose from the condenser.
9. Tilt the top of the condenser to the rear of the vehicle and lift up to remove the condenser.
10. Ensure the lower rubber mounts stay in place in the vehicle.
11. Remove the upper rubber mounts from the condenser.

Scheme 151

Scheme 152

Scheme 153

1. If replacing the condenser, add refrigerant oil to the condenser. Refer to «REFRIGERANT SYSTEM CAPACITIES»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) for system capacity information.
2. Install the upper rubber mounts on the condenser.
3. Install the lower ends of the condenser in to the lower rubber mounts. IMPORTANT: Ensure the upper rubber mounts stay in place on the condenser.
4. Tilt the top of the condenser in to place.
5. Install the new O-ring seals onto the A/C compressor hose and the condenser tube. Refer to «O-RING REPLACEMENT»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
6. Connect the condenser tube to the condenser. NOTE: Refer to «FASTENER NOTICE»(/buick/century/vi-1997-2005/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
7. Tighten the condenser tube nut. Tighten Tighten the nut to 27 N.m (20 lb ft).
8. Connect the A/C compressor hose to the condenser.
9. Install the A/C compressor hose block fitting nut to the condenser. Tighten Tighten the nut to 16 N.m (12 lb ft).
10. Install the radiator. Refer to RADIATOR REPLACEMENT in Engine Cooling.
11. Install the front fender upper diagonal. Refer to BRACE REPLACEMENT - FRONT FENDER UPPER DIAGONAL in Body Front End.
12. Install the air cleaner assembly.
13. Evacuate and recharge the A/C system. Refer to «REFRIGERANT RECOVERY AND RECHARGING»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
14. Leak test the fittings of the component using J 39400-A .

Accumulator Replacement

Tools Required

J 39400-A Halogen Leak Detector. See Special Tools and Equipment .

Scheme 154

Scheme 155

Scheme 156

Scheme 157

1. Recover the refrigerant. Refer to «REFRIGERANT RECOVERY AND RECHARGING»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the air cleaner assembly.
3. Loosen the accumulator hose nut (2) from the accumulator.
4. Disconnect the accumulator hose from the accumulator.
5. Remove the A/C compressor hose block fitting nut (1) from the accumulator.
6. Disconnect the A/C compressor hose from the accumulator.
7. Remove the accumulator bracket retaining bolt.
8. Remove the accumulator bracket bolt clamp.
9. Remove the accumulator from the mounting bracket.

Scheme 158

Scheme 159

Scheme 160

Scheme 161

1. If replacing the accumulator, add refrigerant oil to the accumulator. Refer to «REFRIGERANT SYSTEM CAPACITIES»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) for system capacity information.
2. Install the accumulator to the mounting bracket. NOTE: Refer to «FASTENER NOTICE»(/buick/century/vi-1997-2005/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
3. Tighten the accumulator bracket bolt clamp. Tighten Tighten the bolt to 4 N.m (36 lb in).
4. Install the accumulator.
5. Install the accumulator bracket retaining bolt. Tighten Tighten the bolt to 4 N.m (36 lb in).
6. Install the new O-ring seals onto the A/C compressor hose and the accumulator hose. Refer to «O-RING REPLACEMENT»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
7. Connect the accumulator hose onto the accumulator.
8. Tighten the accumulator hose nut (2). Tighten Tighten the nut to 47 N.m (35 lb ft).
9. Connect the A/C compressor hose to the accumulator.
10. Install the A/C compressor hose nut (1) onto the accumulator. Tighten Tighten the nut to 16 N.m (12 lb ft).
11. Install the air cleaner assembly.
12. Evacuate and recharge the A/C system. Refer to «REFRIGERANT RECOVERY AND RECHARGING»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
13. Leak test the fittings of the component using J 39400-A.

HVAC Module Assembly Replacement

Tools Required

1. J 39400-A Halogen Leak Detector. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. J 38185 Hose Clamp Pliers. See «Special Tools and Equipment»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Scheme 162

Scheme 163

Scheme 164

Scheme 165

Scheme 166

Scheme 167

Scheme 168

Scheme 169

Scheme 170

Scheme 171

Scheme 172

Scheme 173

Scheme 174

Scheme 175

1. Recover the refrigerant. Refer to «REFRIGERANT RECOVERY AND RECHARGING»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Drain the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
3. Remove the fuel injector sight shield (3.8L only). Refer to FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L36) or FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L67) in Engine Mechanical-3.8L.
4. Remove the instrument panel trim pad. Refer to TRIM PAD REPLACEMENT - INSTRUMENT PANEL (I/P) in Instrument Panel, Gages and Console.
5. Remove the passenger side SIR inflator module. Refer to «AIR BAG MODULES»(/buick/century/vi-1997-2005/remont/airbag/#air-bag-restraint-systems)
6. Remove the brake pedal. Refer to «BRAKE PEDAL ASSEMBLY»(/buick/century/vi-1997-2005/remont/mechanical-hydraulic/#disc-brakes-drum-brakes) in Disc & Drum.
7. Disconnect any ground wires, as necessary.
8. Remove the nuts and bolts from the steering column support bracket.
9. Remove the steering column support bracket from the cross vehicle beam.
10. Remove the screws from the right and left side air distribution duct.
11. Remove the right and left side air distribution duct.
12. Remove the bolts from the relay bracket and position the relay bracket aside.
13. Remove the bolts from the BCM bracket and position the BCM bracket aside.
14. Release the wiring harness retaining clips from the cross vehicle beam and position the wiring harness aside.
15. Remove the two screws below the fuse block that support the main wire harness connector to the cross vehicle beam.
16. Remove the bolts from the center support bracket of the HVAC module.
17. Remove the center support bracket of the HVAC module.
18. Remove the bolts from the upper support brackets of the HVAC module.
19. Remove the bolts which secure the left cross vehicle beam to the hinge pillar.
20. Remove the bolts which secure the right cross vehicle beam to the hinge pillar.
21. Remove the bolt (1) from the cross vehicle beam.
22. Remove the cross vehicle beam from the vehicle.
23. Remove the accumulator tube to evaporator core block fitting bolt.
24. Disconnect the accumulator tube from the evaporator.
25. Disconnect the evaporator tube from the evaporator.
26. Remove the O-ring seals and discard.
27. Use J 38185 in order to position aside the heater hose inlet and outlet clamp at the heater core.
28. Disconnect the inlet and outlet heater hose from the heater core. IMPORTANT: Position the heater core outlet cover downward and rearward in order to disconnect the cover from the rear area floor duct assembly.
29. Remove the screws from the heater core outlet cover.
30. Remove the heater core outlet cover.
31. Remove the evaporator drain elbow.
32. Remove the mounting nuts for the HVAC module assembly from the cowl.
33. Disconnect the vacuum hoses from the HVAC module assembly.
34. Disconnect the electrical connectors from the HVAC module assembly.
35. Remove the HVAC module assembly.
36. Remove all of the seals (1,2,3) from the outer HVAC module assembly.

Scheme 176

Scheme 177

Scheme 178

Scheme 179

Scheme 180

Scheme 181

Scheme 182

Scheme 183

Scheme 184

Scheme 185

Scheme 186

Scheme 187

Scheme 188

Scheme 189

Scheme 190

Scheme 191

1. Install new seals (1,2,3) to the outer HVAC module assembly.
2. Install the HVAC module assembly to the vehicle. NOTE: Refer to «FASTENER NOTICE»(/buick/century/vi-1997-2005/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
3. Install the nuts which secure the HVAC module assembly to the dash. Tighten Tighten the nuts to 10 N.m (89 lb in).
4. Install the evaporator drain elbow.
5. Connect the electrical connectors to the HVAC module assembly.
6. Connect the vacuum hoses to the HVAC module assembly.
7. Install the heater core outlet cover.
8. Install the screws to the heater core outlet cover. Tighten Tighten the screws to 1.5 N.m (13 lb in).
9. Install the cross vehicle beam to the vehicle. IMPORTANT: Do NOT tighten the bolts at this time.
10. Install the bolts which secure the right cross vehicle beam to the hinge pillar.
11. Install the bolts which secure the left cross vehicle beam to the hinge pillar. Tighten Tighten the bolts to 20 N.m (15 lb ft).
12. Install the bolt (1) to the cross vehicle beam. Tighten Tighten the bolt to 20 N.m (15 lb ft).
13. Install the bolts to the upper support brackets of the HVAC module. Tighten Tighten the bolts to 10 N.m (89 lb in).
14. Install the center support bracket to the HVAC module.
15. Install the bolts to the center support bracket of the HVAC module. Tighten Tighten the bracket bolts to 10 N.m (89 lb in).
16. Install the instrument panel wiring harness on to the cross vehicle beam and secure the retaining clips.
17. Install the two screws below the fuse block that support the main wire harness connector to the cross vehicle beam.
18. Install the BCM bracket and the bolts. Tighten Tighten the bolts to 10 N.m (89 lb in).
19. Install the relay bracket and the bolts. Tighten Tighten the bolts to 10 N.m (89 lb in).
20. Install the right and left side air distribution ducts.
21. Install the screws to the right and left side air distribution duct. Tighten Tighten the screws to 1.5 N.m (13 lb in).
22. Install the steering column support bracket to the cross vehicle beam.
23. Install the steering column support bracket nuts and bolts. Tighten Tighten the nuts and bolts to 50 N.m (37 lb ft).
24. Install the brake pedal. Refer to «BRAKE PEDAL ASSEMBLY»(/buick/century/vi-1997-2005/remont/mechanical-hydraulic/#disc-brakes-drum-brakes) in Disc & Drum.
25. Connect all disconnected ground wires.
26. Install the passenger side SIR inflator module. Refer to «AIR BAG MODULES»(/buick/century/vi-1997-2005/remont/airbag/#air-bag-restraint-systems)
27. Install the instrument panel trim pad. Refer to TRIM PAD REPLACEMENT - INSTRUMENT PANEL (I/P) in Instrument Panel, Gages and Console.
28. Connect the inlet and outlet heater hose to the heater core. IMPORTANT: Reposition the heater core hose clamps in the indicated location.
29. Use J 38185 in order to reposition the heater hose inlet and outlet clamp to the heater core.
30. Connect the evaporator tube to the evaporator.
31. Connect the accumulator tube to the evaporator.
32. Install the accumulator tube to evaporator core block fitting bolt. Tighten Tighten the bolt to 16 N.m (12 lb ft).
33. Install the fuel injector sight shield (3.8L only). Refer to FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L36) or FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L67) in Engine Mecanical-3.8L.
34. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
35. Evacuate and recharge the A/C system. Refer to «REFRIGERANT RECOVERY AND RECHARGING»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
36. Leak test the fittings of the component using J 39400-A.

Scheme 192

Scheme 193

Scheme 194

1. Remove the HVAC module assembly. Refer to «HVAC MODULE ASSEMBLY REPLACEMENT»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__hvac-module-assembly-replacement) .
2. Remove all of the outer HVAC module assembly seals.
3. Remove the recirculation housing from the HVAC module assembly.
4. Release the retaining clip to the defroster actuator from the HVAC module assembly.
5. Remove the defroster actuator.
6. Remove the HVAC module assembly case upper screws.
7. Separate the HVAC module assembly case (1).
8. Remove the HVAC module assembly seal (2) from the lower module case (1).
9. Remove the evaporator core.
10. Remove the water core filter from the evaporator.

Scheme 195

Scheme 196

Scheme 197

Scheme 198

Scheme 199

Scheme 200

Scheme 201

1. If replacing the evaporator, add refrigerant oil to the evaporator. Refer to «REFRIGERANT SYSTEM CAPACITIES»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) for system capacity information.
2. Install the water core filter to the evaporator.
3. Install a new side seal to the evaporator core.
4. Install a new upper seal to the evaporator core.
5. Install two new lower seals to the evaporator core.
6. Install the HVAC module assembly seal (2) to the lower module case (1).
7. Install the evaporator core into the HVAC module assembly lower case.
8. Align the guide (1) and attach the upper and lower HVAC module assembly case. NOTE: Refer to «FASTENER NOTICE»(/buick/century/vi-1997-2005/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
9. Install the HVAC module assembly upper screws. Tighten Tighten the screws to 1.5 N.m (13 lb in).
10. Install the defroster actuator.
11. Install the recirculation housing to the HVAC module assembly.
12. Install the recirculation housing screws. Tighten Tighten the screws to 1.5 N.m (13 lb in).
13. Install the HVAC module assembly. Refer to «HVAC MODULE ASSEMBLY REPLACEMENT»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__hvac-module-assembly-replacement) .

Heater Hose Replacement - Inlet (3.1L)

Tools Required

J 38185 Hose Clamp Pliers. See Special Tools and Equipment .

Scheme 202

1. Drain the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
2. Remove the fuel injector sight shield. Refer to FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L36) or FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L67) in Engine Mechanical - 3.1L.
3. Use J 38185 in order to reposition the heater hose inlet clamp.
4. Disconnect the heater inlet hose (3) from the inlet pipe.
5. Use J 38185 in order to reposition the heater core inlet hose clamp.
6. Disconnect the heater inlet hose from the heater core.
7. Remove the heater inlet hose.

Scheme 203

1. Install the heater inlet hose.
2. Connect the heater inlet hose to the heater core. IMPORTANT: Reposition heater core hose clamps in the indicated location.
3. Use J 38185 in order to reposition the heater core hose inlet clamp.
4. Connect the heater inlet hose (3) to the inlet pipe.
5. Use J 38185 in order to reposition the heater hose clamp.
6. Install the fuel injector sight shield. Refer to FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L36) or FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L67) in Engine Mechanical - 3.1L.
7. Refill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.

Heater Hose Replacement - Inlet (3.8L)

Tools Required

J 38185 Hose Clamp Pliers. See Special Tools and Equipment .

Scheme 204

Scheme 205

Scheme 206

1. Drain the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
2. Remove the fuel injector sight shield. Refer to FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L36) or FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L67) in Engine Mechanical-3.8L.
3. Use J 38185 in order to position aside the heater hose inlet clamp at the pipe adapter.
4. Disconnect the heater inlet hose from the pipe adapter.
5. Remove the heater hose support bracket nut (1).
6. Use J 38185 in order to position aside the heater core inlet hose clamp.
7. Disconnect the heater inlet hose from the heater core.
8. Separate the support bracket and remove the heater inlet hose.

Scheme 207

Scheme 208

Scheme 209

1. Install the heater inlet hose and support bracket.
2. Connect the heater inlet hose to the heater core. IMPORTANT: Position heater core hose clamps in the indicated location.
3. Use J 38185 in order to secure the heater core hose inlet clamp.
4. Install the heater hose support bracket. NOTE: Refer to «FASTENER NOTICE»(/buick/century/vi-1997-2005/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
5. Install the support bracket nut (1). Tighten Tighten the heater core support bracket nut to 4.5 N.m (40 lb in).
6. Connect the heater inlet hose to the pipe adapter.
7. Use J 38185 in order to secure the heater hose inlet clamp.
8. Install the fuel injector sight shield. Refer to FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L36) or FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L67) in Engine Mechanical-3.8L.
9. Refill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.

Heater Hose Replacement - Outlet (3.1L)

Tools Required

J 38185 Hose Clamp Pliers. See Special Tools and Equipment .

Scheme 210

Scheme 211

1. Drain the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
2. Remove the fuel injector sight shield. Refer to FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L36) or FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L67) in Engine Mechanical - 3.L.
3. Use J 38185 in order to reposition the heater hose outlet clamp.
4. Disconnect the heater outlet hose (2) from the outlet pipe.
5. Use J 38185 in order to reposition the heater core outlet hose clamp.
6. Disconnect the heater outlet hose from the heater core.
7. Remove the heater outlet hose.

Scheme 212

Scheme 213

1. Install the heater outlet hose.
2. Connect the heater outlet hose to the heater core. IMPORTANT: Reposition heater core hose clamps in the indicated location.
3. Use J 38185 in order to reposition the heater core hose outlet clamp.
4. Connect the heater outlet hose (2) to the outlet pipe.
5. Use J 38185 in order to reposition the heater hose outlet clamp.
6. Install the fuel injector sight shield. Refer to FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L36) or FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L67) in Engine Mechanical - 3.1L.
7. Refill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.

Heater Hose Replacement - Outlet (3.8L)

Tools Required

J 38185 Hose Clamp Pliers. See Special Tools and Equipment .

Scheme 214

Scheme 215

Scheme 216

1. Drain the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
2. Remove the fuel injector sight shield. Refer to FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L36) or FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L67) in Engine Mechanical-3.8L.
3. Use J 38185 in order to position aside the heater hose outlet clamp at the pipe adapter.
4. Disconnect the heater outlet hose from the pipe adapter.
5. Remove the heater hose support bracket nut (1).
6. Use J 38185 in order to position aside the heater core outlet hose clamp.
7. Disconnect the heater outlet hose from the heater core.
8. Separate the support bracket and remove the heater outlet hose.

Scheme 217

Scheme 218

Scheme 219

1. Install the heater outlet hose and support bracket.
2. Connect the heater outlet hose to the heater core. IMPORTANT: Position heater core hose clamps in the indicated location.
3. Use J 38185 in order to secure the heater core hose outlet clamp.
4. Install the heater hose support bracket. NOTE: Refer to «FASTENER NOTICE»(/buick/century/vi-1997-2005/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
5. Install the heater hose support bracket nut (1). Tighten Tighten the nut to 4.5 N.m (40 lb in).
6. Connect the heater outlet hose to the pipe adapter.
7. Use J 38185 in order to secure the heater hose outlet clamp.
8. Install the fuel injector sight shield. Refer to FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L36) or FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L67) in Engine Mechanical-3.8L.
9. Refill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.

Heater Pipe Replacement - Inlet (3.1L)

Tools Required

J 38185 Hose Clamp Pliers. See Special Tools and Equipment .

Scheme 220

Scheme 221

1. Drain the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
2. Remove the air cleaner assembly.
3. Disconnect the inlet hose (3) from the inlet pipe.
4. Use J 38185 in order to reposition the heater hose inlet clamp.
5. Remove the inlet pipe mounting nut.
6. Remove the inlet pipe.

Scheme 222

1. Install the heater inlet pipe. NOTE: Refer to «FASTENER NOTICE»(/buick/century/vi-1997-2005/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
2. Install the heater inlet pipe mounting nut. Tighten Tighten the nut to 7 N.m (62 lb in).
3. Connect the inlet hose (3) to the inlet pipe.
4. Use J 38185 in order to reposition the heater hose inlet clamp.
5. Install the air cleaner assembly.
6. Refill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.

Heater Pipe Adapter Replacement - Inlet (3.8L)

Tools Required

J 38185 Hose Clamp Pliers. See Special Tools and Equipment .

Scheme 223

Scheme 224

1. Drain the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
2. Remove the fuel injector sight shield. Refer to FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L36) or FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L67) in Engine Mechanical-3.8L.
3. Disconnect the heater inlet hose from the pipe adapter.
4. Use J 38185 in order to reposition the heater hose clamp.
5. Remove the heater pipe adapter mounting bolt.
6. Remove the heater pipe adapter.

Scheme 225

Scheme 226

1. Lubricate the O-ring with coolant.
2. Install the heater pipe adapter. NOTE: Refer to «FASTENER NOTICE»(/buick/century/vi-1997-2005/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
3. Install the heater inlet pipe adapter mounting bolt. Tighten Tighten the bolt to 6 N.m (53 lb in).
4. Connect the inlet hose to the heater pipe adapter.
5. Use J 38185 in order to reposition the heater core hose clamp.
6. Install the fuel injector sight shield. Refer to FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L67) or FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L67) in Engine Mechanical-3.8L.
7. Refill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.

Heater Pipe Adapter Replacement - Outlet (3.8L)

Tools Required

J 38185 Hose Clamp Pliers. See Special Tools and Equipment .

Scheme 227

Scheme 228

1. Drain the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
2. Remove the fuel injector sight shield. Refer to FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L36) or FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L67) in Engine Mechanical-3.8L.
3. Remove the heater outlet hose from the pipe adapter.
4. Use J 38185 in order to reposition the heater hose clamp.
5. Remove the heater pipe adapter mounting bolt.
6. Remove the heater pipe adapter.

Scheme 229

Scheme 230

1. Lubricate the O-ring with coolant.
2. Install the pipe adapter. NOTE: Refer to «FASTENER NOTICE»(/buick/century/vi-1997-2005/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
3. Install the heater outlet pipe adapter mounting bolt. Tighten Tighten the bolt to 6 N.m (53 lb in).
4. Install the heater outlet hose to the pipe adapter.
5. Use J 38185 in order to reposition the heater core hose clamp.
6. Install the fuel injector sight shield. Refer to FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L36) or FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L67) in Engine Mechanical-3.8L.
7. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.

Scheme 231

1. Position the windshield wipers in the 12 o'clock position, by keying the ignition OFF when the wipers reach the desired position.
2. Position aside the rear hood seal halfway to the center. Refer to SEAL REPLACEMENT - HOOD REAR SIDE in Body Front End.
3. Remove the air inlet grille. Refer to AIR INLET GRILLE PANEL REPLACEMENT in Body Front End.
4. Remove the passenger compartment air filter.

Scheme 232

1. Install the passenger compartment air filter.
2. Install the air inlet grille. Refer to AIR INLET GRILLE PANEL REPLACEMENT in Body Front End.
3. Install the rear hood seal. Refer to SEAL REPLACEMENT - HOOD REAR SIDE in Body Front End.
4. Return the windshield wipers to the PARK position.

Scheme 233

Scheme 234

Scheme 235

1. Remove the right side instrument panel insulator. Refer to CLOSEOUT/INSULATOR PANEL REPLACEMENT - RIGHT in Instrument Panel, Gages and Console.
2. Disconnect the electrical connector from the blower motor resistor.
3. Disconnect the electrical connector from the blower motor. IMPORTANT: The blower motor resistor opening is slotted. Access is extremely limited.
4. Loosen both screws from the forward blower motor resistor.
5. Remove the screws from the rear blower motor resistor.
6. Remove the blower motor resistor.

Scheme 236

Scheme 237

Scheme 238

1. Install the blower motor resistor. NOTE: Refer to «FASTENER NOTICE»(/buick/century/vi-1997-2005/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
2. Install the rear blower motor resistor screw. Tighten Tighten the screw to 1.5 N.m (13 lb in).
3. Tighten the forward blower motor resistor screws. Tighten Tighten the screws to 1.5 N.m (13 lb in).
4. Connect the electrical connector to the blower motor.
5. Connect the electrical connector to the blower motor resistor.
6. Install the right side instrument panel insulator. Refer to CLOSEOUT/INSULATOR PANEL REPLACEMENT - RIGHT in Instrument Panel, Gages and Console.

Scheme 239

Scheme 240

1. Remove the right side instrument panel insulator. Refer to CLOSEOUT/INSULATOR PANEL REPLACEMENT - RIGHT in Instrument Panel, Gages and Console.
2. Release the instrument panel harness retainer and move the harness to one side.
3. Disconnect the blower motor electrical connector.
4. Disconnect the blower motor cooling hose.
5. Remove the mounting screws from the blower motor.
6. Remove the blower motor.

Scheme 241

Scheme 242

1. Install the blower motor. NOTE: Refer to «FASTENER NOTICE»(/buick/century/vi-1997-2005/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
2. Install the blower motor screws. Tighten Tighten the screws to 1.3 N.m (12 lb in).
3. Connect the blower motor cooling hose.
4. Connect the blower motor electrical connector.
5. Install the instrument panel harness into the harness retainer.
6. Install the right side instrument panel insulator. Refer to CLOSEOUT/INSULATOR PANEL REPLACEMENT - RIGHT in Instrument Panel, Gages and Console.

Scheme 243

1. Remove the instrument panel (IP) cluster trim plate. Refer to TRIM PLATE BEZEL REPLACEMENT - INSTRUMENT PANEL (I/P) CLUSTER .
2. Depress the locking retainers on top of the air outlet deflectors using a small flat-bladed tool.
3. From the rear of the trim plate push out the air outlet deflectors.

Scheme 244

1. Position the air outlet deflectors to the opening in the cluster trim plate.
2. Lock the air outlet deflectors to the cluster trim plate correctly.
3. Inspect the I/P air outlet deflectors for correct movement.
4. Install the cluster trim plate. Refer to TRIM PLATE BEZEL REPLACEMENT - INSTRUMENT PANEL (I/P) CLUSTER .

Scheme 245

Scheme 246

1. Remove the instrument panel trim pad. Refer to TRIM PAD REPLACEMENT - INSTRUMENT PANEL (I/P) in Instrument Panel, Gages and Console.
2. Remove the center air duct mounting screw.
3. Remove the center air duct distribution.
4. Remove the side air ducts mounting screws and side air distribution ducts.

Scheme 247

Scheme 248

1. Install the center air distribution duct. NOTE: Refer to «FASTENER NOTICE»(/buick/century/vi-1997-2005/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
2. Install the center air distribution duct mounting screw. Tighten Tighten the screw to 1.5 N.m (13 lb in).
3. Install the right and left side air distribution duct.
4. Install the right and left side air distribution duct mounting screws. Tighten Tighten the screws to 1.5 N.m (13 lb in).
5. Install the instrument panel. Refer to TRIM PAD REPLACEMENT - INSTRUMENT PANEL (I/P) in Instrument Panel, Gages, and Console.

Scheme 249

Scheme 250

Scheme 251

Scheme 252

Scheme 253

Scheme 254

Scheme 255

Scheme 256

1. Remove the instrument panel trim pad. Refer to TRIM PAD REPLACEMENT - INSTRUMENT PANEL (I/P) in Instrument Panel, Gages, and Console.
2. Remove the passenger side SIR inflator module. Refer to «AIR BAG MODULES»(/buick/century/vi-1997-2005/remont/airbag/#air-bag-restraint-systems)
3. Remove the brake pedal. Refer to «BRAKE PEDAL ASSEMBLY»(/buick/century/vi-1997-2005/remont/mechanical-hydraulic/#disc-brakes-drum-brakes) in Disc & Drum.
4. Remove the bolts from the steering column support bracket and remove the bracket.
5. Remove the air distribution duct from the cross vehicle beam. Refer to «AIR DISTRIBUTION DUCT REPLACEMENT»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
6. Remove the bolts from the relay bracket and position the relay bracket aside.
7. Remove the bolts from the BCM bracket and position the BCM bracket aside.
8. Release the wiring harness retaining clips from the cross vehicle beam and position the instrument panel wiring harness aside.
9. Remove the two screws below the fuse block that support the main wire harness connector to the cross vehicle beam.
10. Remove the bolts from the center support bracket of the HVAC module.
11. Remove the center support bracket of the HVAC module.
12. Remove the bolts from the upper support brackets of the HVAC module.
13. Remove the bolts which secure the left cross vehicle beam to the hinge pillar.
14. Remove the bolts which secure the right cross vehicle beam to the hinge pillar.
15. Remove the bolt (1) from the cross vehicle beam.
16. Remove the cross vehicle beam from the vehicle.
17. Remove the defroster duct mounting screws.
18. Remove the defroster duct.

Scheme 257

Scheme 258

Scheme 259

Scheme 260

Scheme 261

Scheme 262

Scheme 263

Scheme 264

Scheme 265

Scheme 266

1. Install the defroster duct. NOTE: Refer to «FASTENER NOTICE»(/buick/century/vi-1997-2005/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
2. Install the mounting screws. Tighten Tighten the screws to 1.5 N.m (13 lb in).
3. Install the defrost distribution ducts to the cross vehicle beam. Refer to «AIR OUTLET REPLACEMENT - DEFROSTER»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. Install the cross vehicle beam to the vehicle.
5. Install the bolts which secure the right cross vehicle beam to the hinge pillar. Tighten the bolts finger tight. NOTE: Refer to «FASTENER NOTICE»(/buick/century/vi-1997-2005/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
6. Install the bolts which secure the left cross vehicle beam to the hinge pillar. Tighten the bolts finger tight. Tighten Tighten the bolts to 20 N.m (15 lb ft).
7. Install the bolt (1) to the cross vehicle beam. Tighten Tighten the bolt to 20 N.m (15 lb ft).
8. Install the bolts to the upper support brackets of the HVAC module. Tighten Tighten the bolts to 10 N.m (89 lb in).
9. Install the center support bracket to the HVAC module.
10. Install the bolts to the center support bracket of the HVAC module. Tighten Tighten the bolts to 10 N.m (89 lb in).
11. Install the instrument panel wiring harness on to the cross vehicle beam and secure the retaining clips.
12. Install the two screws below the fuse block that support the main wire harness connector to the cross vehicle beam.
13. Install the BCM bracket and the bolts. Tighten Tighten the bolts to 10 N.m (89 lb in).
14. Install the relay bracket and the bolts. Tighten Tighten the bolts to 10 N.m (89 lb in).
15. Install the air distribution ducts to the cross vehicle beam. Refer to «AIR DISTRIBUTION DUCT REPLACEMENT»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
16. Install the support bracket for the steering column. Tighten Tighten the nuts to 50 N.m (37 lb ft).
17. Install the brake pedal. Refer to «BRAKE PEDAL ASSEMBLY»(/buick/century/vi-1997-2005/remont/mechanical-hydraulic/#disc-brakes-drum-brakes) in Disc & Drum.
18. Install the passenger side SIR inflator module. Refer to «AIR BAG MODULES»(/buick/century/vi-1997-2005/remont/airbag/#air-bag-restraint-systems) in Air Bag Restraint Systems.
19. Install the instrument panel trim pad. Refer to TRIM PAD REPLACEMENT - INSTRUMENT PANEL (I/P) in Instrument Panel, Gages, and Console.

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Scheme 270

1. Remove the HVAC module assembly. Refer to «HVAC MODULE ASSEMBLY REPLACEMENT»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__hvac-module-assembly-replacement) .
2. Remove the screws retaining the right air temperature actuator.
3. Remove the right air temperature actuator.
4. Remove the screws retaining the left air temperature actuator.
5. Remove the left air temperature actuator.
6. Remove the air inlet housing retaining screws (1).
7. Remove the air inlet housing (2).
8. Remove the HVAC module upper mounting screws.
9. Release the retaining tab (1) and separate the upper and lower module halves.
10. Remove the HVAC module seal that is located between the upper and lower cases. Start to remove the HVAC module case seal (blower motor side of case) seal (2) from the lower module case at the position shown (1). IMPORTANT: The left and right air temperature doors separate in the center.
11. Carefully pull the air temperature doors apart in the center to remove the air temperature door from the HVAC module case. Remove the air temperature doors (1,2).

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Scheme 275

1. Install the air temperature doors (1,2). Carefully align the air temperature door into the HVAC module case.
2. Install the new case seal (2) into the HVAC module case (1). IMPORTANT: Inspect the condition of the retaining tab on the upper module case prior to installing the lower module case. If the retaining tab is broken or damaged, install an external retaining clip, P/N 52458793, or equivalent.
3. Align and install the upper HVAC module case to the lower module case. Align and secure the retaining tab (1) on the upper module case to the retaining slot on the lower module case. NOTE: Refer to «FASTENER NOTICE»(/buick/century/vi-1997-2005/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
4. Install the HVAC module assembly upper mounting screws. Tighten Tighten the screws to 1.5 N.m (13 lb in).
5. Install the recirculation housing (2).
6. Install the recirculation housing retaining screws (1). Tighten Tighten the screws to 1.5 N.m (13 lb in).
7. Position the right air temperature actuator, then align the slots in the electric actuator drive to the flats of the shaft.
8. Align the locating hole to the alignment pin on the HVAC module case.
9. Slide the actuator drive on the shaft. The actuator drive should set completely on the shaft and the mounting holes should be flush with the mounting screws on the HVAC module case. NOTE: Refer to «FASTENER NOTICE»(/buick/century/vi-1997-2005/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
10. Install the screws to the right air temperature actuator. Tighten Tighten the screws to 1.5 N.m (13 lb in).
11. Position the left air temperature actuator, then align the slots in the electric actuator drive to the flats of the shaft.
12. Align the locating hole to the alignment pin on the HVAC module case.
13. Slide the actuator drive on the shaft. The actuator drive should set completely on the shaft and the mounting holes should be flush with the mounting screws on the HVAC module case.
14. Install the screws to the left air temperature actuator. Tighten Tighten the screws to 1.5 N.m (13 lb in).
15. Install the HVAC module assembly. Refer to «HVAC MODULE ASSEMBLY REPLACEMENT»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__hvac-module-assembly-replacement) .

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Scheme 279

1. Remove the HVAC module assembly. Refer to «HVAC MODULE ASSEMBLY REPLACEMENT»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__hvac-module-assembly-replacement) .
2. Remove the screws retaining the left air temperature actuator.
3. Remove the left air temperature actuator.
4. Remove the screws retaining the right air temperature actuator.
5. Remove the right air temperature actuator.
6. Remove the air inlet housing retaining screws (1).
7. Remove the air inlet housing (2).
8. Remove the HVAC module assembly upper mounting screws.
9. Release the retaining tab (1) securing the HVAC module assembly halves.
10. Separate the upper and lower module halves.
11. Remove the HVAC module seal that is located between the upper and lower cases. Start to remove the HVAC module case seal (blower motor side of case) seal (2) from the lower module case at the position shown (1). IMPORTANT: The left and right air temperature doors separate in the center.
12. Carefully pull the air temperature doors apart in the center to remove the air temperature door from the HVAC module case. Remove the air temperature doors (1,2).

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Scheme 283

1. Install the air temperature doors (1,2). Carefully align the air temperature door into the HVAC module case.
2. Install the new case seal (2) to the HVAC module assembly case (1). IMPORTANT: Inspect the condition of the retaining tab on the upper module case prior to installing the lower module case. If the retaining tab is broken or damaged, install an external retaining clip, P/N 52458793, or equivalent.
3. Align and install the upper module case to the lower module case. Align and secure the retaining tab (1). NOTE: Refer to «FASTENER NOTICE»(/buick/century/vi-1997-2005/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
4. Install the HVAC module assembly upper mounting screws. Tighten Tighten the screws to 1.5 N.m (13 lb in).
5. Install the air inlet housing.
6. Install the air inlet housing retaining screws. Tighten Tighten the screws to 1.5 N.m (13 lb in).
7. Position the right air temperature actuator, then align the slots in the electric actuator drive to the flats of the shaft.
8. Align the locating hole to the alignment pin on the HVAC module case.
9. Slide the actuator drive on the shaft. The actuator drive should set completely on the shaft and the mounting holes should be flush with the mounting screws on the HVAC module case. NOTE: Refer to «FASTENER NOTICE»(/buick/century/vi-1997-2005/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
10. Install the screws to the right-air temperature actuator. Tighten Tighten the screws to 1.5 N.m (13 lb in).
11. Position the left air temperature actuator, then align the slots in the electric actuator drive to the flats of the shaft.
12. Align the locating hole to the alignment pin on the HVAC module case.
13. Slide the actuator drive on the shaft. The actuator drive should set completely on the shaft and the mounting holes should be flush with the mounting screws on the HVAC module case.
14. Install the screws to the left air temperature actuator. Tighten Tighten the screws to 1.5 N.m (13 lb in).
15. Install the HVAC module assembly. Refer to «HVAC MODULE ASSEMBLY REPLACEMENT»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__hvac-module-assembly-replacement) .

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1. Remove the instrument panel trim pad. Refer to TRIM PAD REPLACEMENT - INSTRUMENT PANEL (I/P) in Instrument Panel, Gages and Console.
2. Remove the passenger side SIR inflator module. Refer to «AIR BAG MODULES»(/buick/century/vi-1997-2005/remont/airbag/#air-bag-restraint-systems)
3. Remove the brake pedal. Refer to «BRAKE PEDAL ASSEMBLY»(/buick/century/vi-1997-2005/remont/mechanical-hydraulic/#disc-brakes-drum-brakes) in Disc & Drum.
4. Disconnect any ground wires, as necessary.
5. Remove the nuts and bolts from the steering column support bracket.
6. Remove the steering column support bracket from the cross vehicle beam.
7. Remove the screws from the right and left side air distribution ducts.
8. Remove the air distribution ducts.
9. Remove the bolts from the relay bracket and position the relay bracket aside.
10. Remove the bolts from the BCM bracket and position the BCM bracket aside.
11. Release the wiring harness retaining clips from the cross vehicle beam and position the wiring harness aside.
12. Remove the two screws below the fuse block that hold the main harness connector to the cross vehicle beam.
13. Remove the bolts from the center support bracket of the HVAC module.
14. Remove the center support bracket of the HVAC module.
15. Remove the bolts from the upper support brackets of the HVAC module.
16. Remove the bolts which secure the left cross vehicle beam to the hinge pillar.
17. Remove the bolts which secure the right cross vehicle beam to the hinge pillar.
18. Remove the bolt (1) from the cross vehicle beam.
19. Remove the cross vehicle beam from the vehicle.
20. Disconnect the 2 vacuum lines from the defroster actuator (3).
21. Disconnect the orange vacuum line from the recirculation actuator and install a hand vacuum pump (2).
22. Remove the defroster actuator from the attachment to the HVAC module case.
23. Using the hand vacuum pump (2) open the recirculation actuator door.
24. Rotate the defroster actuator to the right and up into the opening between the back of the dash and the opening into the HVAC module. The opening which results when the recirculation actuator door is in the full open position.
25. Disconnect the defroster actuator from the defroster door arm.
26. Remove the retaining screws (1) from the air distribution case cover.
27. Remove the air distribution case cover (2).
28. Remove and discard the air distribution case seal.
29. Remove the linkage between the defroster door and the vent door on the left side of the HVAC module assembly.
30. Remove the defroster door (1).

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1. Install the defroster door (1).
2. Connect the linkage between the defroster door and the vent door.
3. Install a new air distribution case seal.
4. Install the air distribution case cover (2). NOTE: Refer to «FASTENER NOTICE»(/buick/century/vi-1997-2005/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
5. Install the air distributor cover retaining screws (1). Tighten Tighten the screws to 1.5 N.m (13 lb in).
6. Connect the orange vacuum line to a hand vacuum pump (2).
7. Using the hand vacuum pump (2) open the recirculation actuator door.
8. Rotate the defroster actuator to the right and up into the opening between the back of the dash and the opening into the HVAC module. The opening which results when the recirculation actuator door is in the full open position.
9. Connect the defroster actuator to the defroster door arm.
10. Position the defroster actuator on to the mounting slides of the HVAC module assembly.
11. Ensure that the lock tab locks the defroster actuator in place.
12. Connect the vacuum lines to the defroster actuator.
13. Connect the vacuum line to the recirculation actuator.
14. Install the cross vehicle beam to the vehicle.
15. Install the bolts which secure the right cross vehicle beam to the hinge pillar. Tighten the bolts finger tight.
16. Install the bolts which secure the left cross vehicle beam to the hinge pillar. Tighten the bolts finger tight. Tighten Tighten all the bolts to 20 N.m (15 lb ft).
17. Install the bolt (1) to the cross vehicle beam. Tighten Tighten the bolt to 20 N.m (15 lb ft).
18. Install the bolts to the upper support brackets of the HVAC module. Tighten Tighten the bolts to 10 N.m (89 lb in).
19. Install the center support bracket to the HVAC module.
20. Install the bolts to the center support bracket of the HVAC module. Tighten Tighten the bolts to 10 N.m (89 lb in).
21. Install the instrument panel wiring harness on to the cross vehicle beam and secure the retaining clips.
22. Install the two screws below the fuse block that hold the main wire harness connector to the cross vehicle beam.
23. Install the BCM bracket and the bolts. Tighten Tighten the bolts to 10 N.m (89 lb in).
24. Install the relay bracket and the bolts. Tighten Tighten the bolts to 10 N.m (89 lb in).
25. Install the right and left side air distribution duct bolts. Tighten Tighten the bolts to 1.5 N.m (13 lb in).
26. Install the steering column support bracket to the cross vehicle beam.
27. Install the nuts and bolts to the steering column support bracket. Tighten Tighten the nuts and bolts to 50 N.m (37 lb ft).
28. Install the brake pedal. Refer to «BRAKE PEDAL ASSEMBLY»(/buick/century/vi-1997-2005/remont/mechanical-hydraulic/#disc-brakes-drum-brakes) in Disc & Drum.
29. Connect all disconnected ground wires.
30. Install the passenger side SIR inflator module. Refer to «AIR BAG MODULES»(/buick/century/vi-1997-2005/remont/airbag/#air-bag-restraint-systems)
31. Install the instrument panel trim pad. Refer to TRIM PAD REPLACEMENT - INSTRUMENT PANEL (I/P) in Instrument Panel, Gages and Console.

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1. Remove the instrument panel trim pad. Refer to TRIM PAD REPLACEMENT - INSTRUMENT PANEL (I/P) in Instrument Panel, Gages and Console.
2. Remove the passenger side SIR inflator module. Refer to «AIR BAG MODULES»(/buick/century/vi-1997-2005/remont/airbag/#air-bag-restraint-systems)
3. Remove the brake pedal. Refer to «BRAKE PEDAL ASSEMBLY»(/buick/century/vi-1997-2005/remont/mechanical-hydraulic/#disc-brakes-drum-brakes) in Disc & Drum.
4. Disconnect any ground wires, as necessary.
5. Remove the nuts and bolts from the steering column support bracket.
6. Remove the steering column support bracket from the cross vehicle beam.
7. Remove the screws from the right and left side air distribution ducts.
8. Remove the air distribution ducts.
9. Remove the bolts from the relay bracket and position the relay bracket aside.
10. Remove the bolts from the BCM bracket and position the BCM bracket aside.
11. Release the wiring harness retaining clips from the cross vehicle beam and position the wiring harness aside.
12. Remove the two screws below the fuse block that hold the main harness connector to the cross vehicle beam.
13. Remove the bolts from the center support bracket of the HVAC module.
14. Remove the center support bracket of the HVAC module.
15. Remove the bolts from the upper support brackets of the HVAC module.
16. Remove the bolts which secure the left cross vehicle beam to the hinge pillar.
17. Remove the bolts which secure the right cross vehicle beam to the hinge pillar.
18. Remove the bolt (1) from the cross vehicle beam.
19. Remove the cross vehicle beam from the vehicle.
20. Disconnect the vacuum lines from the mode actuator.
21. Lift the lock tab up (1) to remove the actuator.
22. Remove the mode actuator off the slides of the HVAC module assembly.
23. Disconnect the actuator pushrod from the mode door lever and remove the actuator.
24. Remove the air distribution case cover retaining screws (1).
25. Remove the air distribution case cover (2).
26. Remove and discard the air distribution case seal.
27. Remove the mode door (2).

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1. Install the mode door (2).
2. Install a new air distribution case seal.
3. Install the air distribution case cover (2). NOTE: Refer to «FASTENER NOTICE»(/buick/century/vi-1997-2005/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
4. Install the air distributor cover retaining screws (1). Tighten Tighten the screws to 1.5 N.m (13 lb in).
5. Connect the mode actuator pushrod to the mode door lever.
6. Position the mode actuator on to the mounting slides of the HVAC module assembly.
7. Ensure that the lock tab locks the defroster actuator in place.
8. Connect the vacuum lines to the mode actuator.
9. Install the cross vehicle beam to the vehicle.
10. Install the bolts which secure the right cross vehicle beam to the hinge pillar. Tighten the bolts finger tight.
11. Install the bolts which secure the left cross vehicle beam to the hinge pillar. Tighten the bolts finger tight. Tighten Tighten the bolts to 20 N.m (15 lb ft).
12. Install the bolt (1) to the cross vehicle beam. Tighten Tighten the bolt to 20 N.m (15 lb ft).
13. Install the bolts to the upper support brackets of the HVAC module. Tighten Tighten the bolts to 10 N.m (89 lb in).
14. Install the center support bracket to the HVAC module.
15. Install the bolts to the center support bracket of the HVAC module. Tighten Tighten the bolts to 10 N.m (89 lb in).
16. Install the instrument panel wiring harness on to the cross vehicle beam and secure the retaining clips.
17. Install the two screws below the fuse block that hold the main wire harness connector to the cross vehicle beam.
18. Install the BCM bracket and the bolts. Tighten Tighten the bolts to 10 N.m (89 lb in).
19. Install the relay bracket and the bolts. Tighten Tighten the bolts to 10 N.m (89 lb in).
20. Install the right and left side air distribution ducts.
21. Install the right and left side air distribution duct bolts. Tighten Tighten the bolts to 1.5 N.m (13 lb in).
22. Install the steering column support bracket to the cross vehicle beam.
23. Install the nuts and bolts to the steering column support bracket. Tighten Tighten the nuts and bolts to 50 N.m (37 lb ft).
24. Install the brake pedal. Refer to «BRAKE PEDAL ASSEMBLY»(/buick/century/vi-1997-2005/remont/mechanical-hydraulic/#disc-brakes-drum-brakes) in Disc & Drum.
25. Connect all disconnected ground wires.
26. Install the passenger side SIR inflator module. Refer to «AIR BAG MODULES»(/buick/century/vi-1997-2005/remont/airbag/#air-bag-restraint-systems)
27. Install the instrument panel trim pad. Refer to TRIM PAD REPLACEMENT - INSTRUMENT PANEL (I/P) in Instrument Panel, Gages and Console.

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Scheme 335

1. Remove the vacuum tank. Refer to VACUUM TANK REPLACEMENT in HVAC System - Manual.
2. Remove the floor carpet. Refer to CARPET REPLACEMENT - FRONT in Interior Trim.
3. Remove the rear floor air outlet duct (1) from the holes in the floor reinforcement.
4. Disconnect the rear floor air outlet duct from the heater core outlet cover.
5. Remove the bolts from the vacuum harness bracket and position bracket aside.
6. Remove the heater outlet cover screws.
7. Remove the heater outlet cover.
8. Disconnect the defroster/vent door link at the vent door on the left side of the HVAC module assembly.
9. Remove the heater core cover screws.
10. Remove the heater core cover.
11. Remove the vent door (1) from the HVAC module assembly.

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Scheme 339

1. Install the vent door (1) to the HVAC module assembly.
2. Install the heater core cover. NOTE: Refer to «FASTENER NOTICE»(/buick/century/vi-1997-2005/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
3. Install the heater core cover screws. Tighten Tighten the screws to 1.5 N.m (13 lb in).
4. Install the heater core outlet cover.
5. Install the screws to the heater core outlet cover. Tighten Tighten the screws to 1.5 N.m (13 lb in).
6. Install the HVAC vacuum harness bracket.
7. Install the screws to the HVAC vacuum harness bracket. Tighten Tighten the screws to 1.5 N.m (13 lb in).
8. Connect the defroster/vent door link at the vent door on the left side of the HVAC module assembly.
9. Connect the rear floor air outlet duct to the heater core outlet cover.
10. Install the rear floor air outlet duct (1) to the holes in the floor reinforcement.
11. Install the floor carpet. Refer to CARPET REPLACEMENT - FRONT in Interior Trim.
12. Install the vacuum tank. Refer to VACUUM TANK REPLACEMENT in HVAC System - Manual.

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Scheme 341

1. Remove the HVAC module assembly. Refer to «HVAC MODULE ASSEMBLY REPLACEMENT»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__hvac-module-assembly-replacement) .
2. Disconnect the vacuum line from the recirculation actuator.
3. Lift the retaining tab and slide the recirculation actuator off the mounting slides.
4. Disconnect the recirculation actuator plunger rod from the recirculation actuator lever and remove the actuator.
5. Remove the recirculation housing retaining screws (1).
6. Remove the recirculation housing (2) from the HVAC module assembly.
7. Remove the recirculation door (1) from the recirculation housing (2).

Scheme 342

Scheme 343

1. Install the recirculation door.
2. Align the retaining tabs and install the recirculation housing (2) to the HVAC module assembly. NOTE: Refer to «FASTENER NOTICE»(/buick/century/vi-1997-2005/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
3. Install the recirculation housing screws. Tighten Tighten the screws to 1.5 N.m (13 lb in).
4. Connect the recirculation actuator plunger rod to the recirculation actuator lever.
5. Position the recirculation actuator on to the mounting slides of the HVAC module assembly.
6. Ensure that the lock tab locks the recirculation actuator in place.
7. Connect the vacuum line to the recirculation actuator.
8. Install the HVAC module assembly. Refer to «HVAC MODULE ASSEMBLY REPLACEMENT»(/buick/century/vi-1997-2005/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__hvac-module-assembly-replacement) .

Heater Core Replacement

Tools Required

J 38185 Hose Clamp Pliers. See Special Tools and Equipment .

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1. For a 3.8L engine, remove the fuel injector sight shield. Refer to FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L36) or FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L67) in Engine Mechanical-3.8L. Drain the coolant. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
2. Use J 38185 in order to position aside the heater hose inlet and outlet clamp at the heater core.
3. Disconnect the inlet and outlet heater hose from the heater core.
4. Remove the vacuum tank. Refer to VACUUM TANK REPLACEMENT in HVAC System - Manual.
5. Remove the floor carpet. Refer to CARPET REPLACEMENT - FRONT in Interior Trim.
6. Remove the rear floor air outlet duct from the holes in the floor reinforcement.
7. Disconnect the rear floor air outlet duct from the heater core outlet cover.
8. Remove the bolts from the vacuum harness bracket and position bracket aside. IMPORTANT: Position the heater core outlet cover downward and rearward in order to disconnect the cover from the rear area floor duct assembly.
9. Remove the screws from the heater core outlet cover.
10. Remove the heater core outlet cover.
11. Remove the screws from the heater core cover.
12. Remove the heater core cover.
13. Remove and discard the seals (1,2) from the heater core cover.
14. Remove the caulk (3) from the heater core cover.
15. Remove and discard the outer seal (5) from the heater core.
16. Remove the screw (1) from the heater core support bracket.
17. Remove the heater core support bracket.
18. Remove the screw (2) from the heater core pipe retainer clamp.
19. Remove the heater core from the HVAC lower case.
20. Remove the heater core pipe retainer clamp from the heater core pipes.
21. Remove and discard the lower seal (4) from the HVAC case.
22. Remove and discard the center seal (3) from the HVAC case.
23. Remove and discard the upper seal (2) from the HVAC lower case.
24. Remove and discard the side seals (1) from the HVAC lower case.

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1. Install the side seals (1) to the HVAC lower case.
2. Install the upper seal (2) to the HVAC lower case.
3. Install the center seal (3) to the HVAC case.
4. Install the lower seal (4) to the HVAC case.
5. Install the heater core pipe retainer clamp to the heater core pipes.
6. Install the heater core to the HVAC lower case. NOTE: Refer to «FASTENER NOTICE»(/buick/century/vi-1997-2005/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
7. Install the screw (2) to the heater core retainer clamp. Tighten Tighten the screw to 1.5 N.m (13 lb in).
8. Install the screw (1) to the heater core support bracket. Tighten Tighten the screw to 1.5 N.m (13 lb in).
9. Install outer seal (5) to the heater core.
10. Install new seals number (1) and (2) to the heater core cover.
11. Install the caulk (3) on to the heater core cover.
12. Install the heater core cover.
13. Install the heater core cover screws. Tighten Tighten the screws to 1.5 N.m (13 lb in).
14. Install the heater core outlet cover.
15. Install the screws to the heater core outlet cover. Tighten Tighten the screws to 1.5 N.m (13 lb in).
16. Install the HVAC vacuum harness bracket.
17. Install the screws to the HVAC vacuum harness bracket. Tighten Tighten the screws to 10 N.m (89 lb in).
18. Connect the rear floor air outlet duct to the heater core outlet cover.
19. Install the rear floor air outlet duct to the holes in the floor reinforcement.
20. Install the floor carpet. Refer to CARPET REPLACEMENT - FRONT in Interior Trim.
21. Install the vacuum tank. Refer to VACUUM TANK REPLACEMENT in HVAC System - Manual.
22. Connect the inlet and outlet heater hose to the heater core. IMPORTANT: Reposition the heater core hose clamps in the indicated location.
23. Use J 38185 in order to reposition the heater hose inlet and outlet clamp to the heater core.
24. For a 3.8L engine, install the fuel injector sight shield. Refer to FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L36) or Fuel Injector Sight Shield Replacement (L67) in Engine Mechanical - 3.8L.
25. Fill the coolant. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.

Scheme 366

1. Remove the floor carpet. Refer to CARPET REPLACEMENT - FRONT in Interior Trim.
2. Release the rear floor air outlet duct (1) from the floor.
3. Disconnect the rear floor air outlet duct from the heater outlet cover.
4. Remove the rear floor air outlet duct.

Scheme 367

1. Install the rear floor air outlet duct (1).
2. Connect the rear floor air outlet duct from the heater outlet cover.
3. Position the floor duct into holes in floor reinforcement and press into place.
4. Install the floor carpet. Refer to CARPET REPLACEMENT - FRONT in Interior Trim.

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See also:
• DIAGNOSTIC SYSTEM CHECK - HVAC SYSTEMS - MANUAL
• DIAGNOSTIC SYSTEM CHECK - HVAC SYSTEMS - AUTO
• JACKING AND LIFTING THE VEHICLE
• SPLASH SHIELD REPLACEMENT -- ENGINE
• FASTENER NOTICE
• LIFTING AND JACKING THE VEHICLE
• VACUUM BRAKE BOOSTER
• AIR BAG MODULES
• BRAKE PEDAL ASSEMBLY
• Special Tools and Equipment
• REFRIGERANT RECOVERY AND RECHARGING
• EXPANSION (ORIFICE) TUBE REPLACEMENT
• COMPRESSOR REPLACEMENT (3.1L)
• COMPRESSOR REPLACEMENT (3.8L)
• COMPRESSOR CLUTCH PLATE AND HUB ASSEMBLY REMOVAL (V5 - DIRECT MOUNT)
• CLUTCH ROTOR AND/OR BEARING REMOVAL (V5 - DIRECT MOUNT)
• COMPRESSOR LEAK TESTING (V5 DIRECT MOUNT)
• COMPRESSOR LEAK TESTING (V5 - CONVENTIONAL MOUNT)
• CLUTCH ROTOR AND/OR BEARING INSTALL (V5 - DIRECT MOUNT)
• COMPRESSOR CLUTCH PLATE/HUB ASSEMBLY INSTALL (V5 - DIRECT MOUNT)
• CONDENSER TUBE REPLACEMENT
• HVAC MODULE ASSEMBLY REPLACEMENT